Dodge - Ram 2500 4wd - Workshop Manual - 2008 - 2008

Factory Workshop Manual Make Dodge Model Ram 2500 4wd Engine and year Truck L6-6.7L DSL Turbo (2008) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 213 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Circuit Description 1 G20 20VT/BR IGNITION SWITCH SENSE 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 4 Z109 20BK/GY GROUND 5 A114 18GY/RD FUSED B(+) 6 D55 20WT/OR CAN B BUS (+) 7 D54 20WT CAN B BUS (-) 8-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7 Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 10 Keyless Entry Module: Diagrams Component ID: 213 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Circuit Description 1 G20 20VT/BR IGNITION SWITCH SENSE 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 4 Z109 20BK/GY GROUND 5 A114 18GY/RD FUSED B(+) 6 D55 20WT/OR CAN B BUS (+) 7 D54 20WT CAN B BUS (-) 8-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 11 Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 12 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module Keyless Entry Module: Description and Operation Remote Keyless Entry Module Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Programming and Relearning Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module > Page 16 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. See: Body and Frame/Locks/Power Locks/Description and Operation/Description . The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module > Page 17 to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key ; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. . The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 18 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module Keyless Entry Module: Service and Repair Remote Keyless Entry Module Removal REMOVAL See: Sentry Key Remote Entry Module/Removal Installation INSTALLATION See: Sentry Key Remote Entry Module/Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module > Page 21 Keyless Entry Module: Service and Repair Sentry Key Remote Entry Module Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module > Page 22 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module > Page 23 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module > Page 24 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Towing Module > Component Information > Locations Towing Module: Locations Component ID: 203 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Circuit Description 1 Z998 18BK GROUND 2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 3 B40 14DG TRAILER TOW BRAKE B(+) 4 A400 14TN/RD FUSED B(+) Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Towing Module > Component Information > Locations > Page 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Towing Module > Component Information > Locations > Page 29 Towing Module: Diagrams Component ID: 203 Component : MODULE-BRAKE PROVISION Connector: Name : MODULE-BRAKE PROVISION Color : BLUE # of pins : 4 Pin Circuit Description 1 Z998 18BK GROUND 2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 3 B40 14DG TRAILER TOW BRAKE B(+) 4 A400 14TN/RD FUSED B(+) Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Towing Module > Component Information > Locations > Page 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > Customer Interest for Voice Activation Module: > 08-028-08 > Sep > 08 > Cell Phone - Voice Recognition Screen Locks Up Voice Activation Module: Customer Interest Cell Phone - Voice Recognition Screen Locks Up NUMBER: 08-028-08 GROUP: Electrical DATE: September 18, 2008 SUBJECT: Voice Recognition Screen Lock-up on REN or REZ Radio Equipped With Hands-Free Communications OVERVIEW: This bulletin involves replacing the Hands Free Module (HFM). MODELS: 2008 (DR/DH/DC/D1) Ram Truck (1500/2500/3500) 2008 (HB) Durango 2008 (HG) Aspen 2008 (JS) Avenger/Sebring (U.S. and International Markets) 2008 (KA) Nitro (U.S. and International Markets) 2008 (KK) Liberty (U.S. and International Markets) 2008 (LX) 300C/Magnum/Charger 2008 (LE) 300/ 300C Touring (International Markets) 2008 (LC) Challenger 2008 (RI) Town & Country/Grand Caravan/Grand Voyager (U.S. and International Markets) 2008 (WK) Grand Cherokee 2008 (WH) Grand Cherokee (International Markets) 2008 (XK) Commander 2008 (XH) Commander (International Markets) NOTE: This bulletin applies to vehicles equipped with radio sales codes REN or REZ and Hands4ree Communications Sales Codes RSP or RSQ built before the following dates: ^ (HB/HG) built before November 13, 2007 (MDH 1113XX) ^ (LX/LC) built before February 28, 2008 (MDH 0228XX) ^ (DR) built before January 26, 2008 (MDH 0126XX) ^ (WK/XK) built before March 2, 2008 (MDH 0302XX) ^ (LE, WH/XH, DH, DC, D1) built before November 6, 2007 (MDH 1106XX) ^ (JS) built before May 6, 2008 (MDH 0506XX) ^ (RT) built before December 13, 2007 (MDH 1213XX) ^ (KK/KA) built before February 26, 2008 (MDH 0226XX) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > Customer Interest for Voice Activation Module: > 08-028-08 > Sep > 08 > Cell Phone - Voice Recognition Screen Locks Up > Page 39 SYMPTOM/CONDITION: Customers may experience one of the following conditions: a. A "lock up condition of the radio screen when the Voice Recognition (VR) button is pressed b. When the VR button is pressed, the radio display changes to the phone screen and there is a lack of the "Ready" audio prompt. If the above symptom/condition is experienced, perform the following diagnostic procedure. DIAGNOSIS: 1. Turn ignition key on. 2. Using a Scan Tool (StarSCAN(R)) read and identify the current HFM part number in the vehicle. 3. Is the HFM part number 05064560AC, 05064448AE, 05064561AC, 05064482AE, 05064483AE or greater? a. Yes >> This bulletin does not apply, further diagnosis is required. b. No >> perform the repair procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Replace the Hands Free Module. Refer to the service procedure available on DealerCONNECT/TechCONNECT, Group 8 Electrical > 8T Navigation and Telecommunications> MODULE, Hands free remove and Installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > Customer Interest for Voice Activation Module: > 08-028-08 > Sep > 08 > Cell Phone - Voice Recognition Screen Locks Up > Page 40 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Voice Activation Module: > 08-028-08 > Sep > 08 > Cell Phone - Voice Recognition Screen Locks Up Voice Activation Module: All Technical Service Bulletins Cell Phone - Voice Recognition Screen Locks Up NUMBER: 08-028-08 GROUP: Electrical DATE: September 18, 2008 SUBJECT: Voice Recognition Screen Lock-up on REN or REZ Radio Equipped With Hands-Free Communications OVERVIEW: This bulletin involves replacing the Hands Free Module (HFM). MODELS: 2008 (DR/DH/DC/D1) Ram Truck (1500/2500/3500) 2008 (HB) Durango 2008 (HG) Aspen 2008 (JS) Avenger/Sebring (U.S. and International Markets) 2008 (KA) Nitro (U.S. and International Markets) 2008 (KK) Liberty (U.S. and International Markets) 2008 (LX) 300C/Magnum/Charger 2008 (LE) 300/ 300C Touring (International Markets) 2008 (LC) Challenger 2008 (RI) Town & Country/Grand Caravan/Grand Voyager (U.S. and International Markets) 2008 (WK) Grand Cherokee 2008 (WH) Grand Cherokee (International Markets) 2008 (XK) Commander 2008 (XH) Commander (International Markets) NOTE: This bulletin applies to vehicles equipped with radio sales codes REN or REZ and Hands4ree Communications Sales Codes RSP or RSQ built before the following dates: ^ (HB/HG) built before November 13, 2007 (MDH 1113XX) ^ (LX/LC) built before February 28, 2008 (MDH 0228XX) ^ (DR) built before January 26, 2008 (MDH 0126XX) ^ (WK/XK) built before March 2, 2008 (MDH 0302XX) ^ (LE, WH/XH, DH, DC, D1) built before November 6, 2007 (MDH 1106XX) ^ (JS) built before May 6, 2008 (MDH 0506XX) ^ (RT) built before December 13, 2007 (MDH 1213XX) ^ (KK/KA) built before February 26, 2008 (MDH 0226XX) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Voice Activation Module: > 08-028-08 > Sep > 08 > Cell Phone - Voice Recognition Screen Locks Up > Page 46 SYMPTOM/CONDITION: Customers may experience one of the following conditions: a. A "lock up condition of the radio screen when the Voice Recognition (VR) button is pressed b. When the VR button is pressed, the radio display changes to the phone screen and there is a lack of the "Ready" audio prompt. If the above symptom/condition is experienced, perform the following diagnostic procedure. DIAGNOSIS: 1. Turn ignition key on. 2. Using a Scan Tool (StarSCAN(R)) read and identify the current HFM part number in the vehicle. 3. Is the HFM part number 05064560AC, 05064448AE, 05064561AC, 05064482AE, 05064483AE or greater? a. Yes >> This bulletin does not apply, further diagnosis is required. b. No >> perform the repair procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Replace the Hands Free Module. Refer to the service procedure available on DealerCONNECT/TechCONNECT, Group 8 Electrical > 8T Navigation and Telecommunications> MODULE, Hands free remove and Installation procedures. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Voice Activation Module: > 08-028-08 > Sep > 08 > Cell Phone - Voice Recognition Screen Locks Up > Page 47 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > Page 48 Voice Activation Module: Locations Component ID: 208 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Circuit Description 1 A114 18GY/RD FUSED B(+) 2-3-4 D54 20WT CAN B BUS (-) 5 X722 20LB/DG MICROPHONE 2 IN (+) 6-7-- 8 X716 20GY/TN LEFT AUDIO OUTPUT 9 X776 20TN/GY RIGHT AUDIO OUTPUT 10 X795 20DG COMMON AUDIO OUTPUT 11 - 12 - 13 - 14 D55 20WT/OR CAN B BUS (+) 15 - 16 X712 20DG/LB MICROPHONE 1 IN (+) 17 X792 20LB/DG MICROPHONE IN (-) 18 - 19 - 20 X793 20DG/YL MICROPHONE FEED 21 X835 20OR/GY SENSOR GROUND 22 Z970 18BK GROUND Component Location - 46 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > Page 49 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > Page 50 Voice Activation Module: Diagrams Component ID: 208 Component : MODULE-HANDS FREE Connector: Name : MODULE-HANDS FREE Color : DK. GRAY # of pins : 22 Pin Circuit Description 1 A114 18GY/RD FUSED B(+) 2-3-4 D54 20WT CAN B BUS (-) 5 X722 20LB/DG MICROPHONE 2 IN (+) 6-7-- 8 X716 20GY/TN LEFT AUDIO OUTPUT 9 X776 20TN/GY RIGHT AUDIO OUTPUT 10 X795 20DG COMMON AUDIO OUTPUT 11 - 12 - 13 - 14 D55 20WT/OR CAN B BUS (+) 15 - 16 X712 20DG/LB MICROPHONE 1 IN (+) 17 X792 20LB/DG MICROPHONE IN (-) 18 - 19 - 20 X793 20DG/YL MICROPHONE FEED 21 X835 20OR/GY SENSOR GROUND 22 Z970 18BK GROUND Component Location - 46 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Technical Service Bulletins > Page 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Description and Operation Winch Relay: Description and Operation DESCRIPTION RELAY PACK Electrical operation of the control assembly consists of four heavy duty relays, a thermal-switch located on the motor armature brush holder and a Low Voltage Interrupt (LVI) located in the control assembly. The thermal-switch interrupts the power-in function and the LVI affects both the power-in and power-out functions and must be reset by allowing the charging circuit voltage to rise above 10 volts for more than 30 seconds. The thermal switch is reset only by allowing the winch motor to cool adequately (about 30 minutes). Relay number 1 and 3 control current flow through the field windings and relay number 2 and 4 supply current to the motor armature. Operation In the power-out mode, relay number 2 and 3 are energized by the remote control switch. Current flows from the positive battery terminal through relay number 3 then through the black motor cable to the number 2 and number 1 field windings. From the black motor cable current then flows through solenoid number 2 to the motor armature to ground. In power-in mode, relay number 1 and 4 are energized. Current again flows from the battery positive cable, but this time current flows through solenoid number 1 then through field winding number 1. Current flowing in the reverse direction through the field windings cause the motor to turn in the opposite direction. From the red motor cable current then flows through relay number 4 to the black cable going to the motor armature to ground. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay Winch Relay: Service and Repair Relay Removal REMOVAL 1. Remove the relay pack (1). See: Relay Pack/Removal 2. Remove the nuts (2 & 3), disconnect the cables and remove the bus straps (4). NOTE: Relay #4 shown, all others similar. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 57 3. Remove the nuts (1) and disconnect the control wires (2). 4. Slide the relay (1) out of the retaining tab (2) and remove. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Slide the relay (1) into the retaining tab (2). 2. Install the control wires (2) and install the nuts (1). 3. Tighten the nuts to 3 Nm (25 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 58 4. Install the bus straps (4) and connect the cables. 5. Install the nuts (2 & 3) and tighten to 9.5 Nm (85 in. lbs.). 6. Install the relay pack (1). See: Relay Pack/Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 59 Winch Relay: Service and Repair Relay Pack Removal REMOVAL 1. Disconnect and isolate battery negative cable (3). 2. Remove the winch assembly (2). See: Accessories and Optional Equipment/Winch/Service and Repair/Winch/Removal 3. Remove the nut and disconnect the red battery positive cable (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 60 NOTE: Relay #4 shown, all others similar. 4. Remove the control wire nuts (1) and disconnect the control wires (2) from each relay. Installation INSTALLATION NOTE: Relay #4 shown, all others similar. 1. Install the control wires (2) to all the relays and install the nuts (1). 2. Tighten the nuts to 3 Nm (25 in. lbs.). 3. Install the red battery positive cable (1) and install the switch wire. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Winch Relay > Component Information > Service and Repair > Relay > Page 61 4. Install the nut and tighten to 10 Nm (85 in. lbs.). 5. Install the relay pack cover (1) and install the three screws (2). 6. Install the winch assembly (2). See: Accessories and Optional Equipment/Winch/Service and Repair/Winch/Installation 7. Connect the battery negative cable (3) and verify winch operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component ID: 213 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Circuit Description 1 G20 20VT/BR IGNITION SWITCH SENSE 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 4 Z109 20BK/GY GROUND 5 A114 18GY/RD FUSED B(+) 6 D55 20WT/OR CAN B BUS (+) 7 D54 20WT CAN B BUS (-) 8-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 66 Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 67 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 68 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 69 Keyless Entry Module: Diagrams Component ID: 213 Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM Connector: Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM Color : BLACK # of pins : 8 Pin Circuit Description 1 G20 20VT/BR IGNITION SWITCH SENSE 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 4 Z109 20BK/GY GROUND 5 A114 18GY/RD FUSED B(+) 6 D55 20WT/OR CAN B BUS (+) 7 D54 20WT CAN B BUS (-) 8-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 70 Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 71 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 72 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module Keyless Entry Module: Description and Operation Remote Keyless Entry Module Description DESCRIPTION When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Operation OPERATION Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Programming and Relearning Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module > Page 75 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. See: Body and Frame/Locks/Power Locks/Description and Operation/Description . The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM)/Engine Control Module (ECM) or the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Remote Keyless Entry Module > Page 76 to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM or ECM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key ; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. . The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 77 Keyless Entry Module: Testing and Inspection REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module Keyless Entry Module: Service and Repair Remote Keyless Entry Module Removal REMOVAL See: Sentry Key Remote Entry Module/Removal Installation INSTALLATION See: Sentry Key Remote Entry Module/Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module > Page 80 Keyless Entry Module: Service and Repair Sentry Key Remote Entry Module Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module > Page 81 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module > Page 82 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Remote Keyless Entry Module > Page 83 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Component ID: 201 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Circuit Description 1-2 A111 16DG/RD FUSED B(+) 3 D65 20WT/LG CAN C BUS (+) 4-5-6-- 7-8-9-10 - 11 - 12 B9 20DG/LG LEFT FRONT WHEEL SPEED SENSOR (+) 13 B8 20DG/TN LEFT FRONT WHEEL SPEED SENSOR (-) 14 B401 20DG/BR TRAILER TOW DAMPING RELAY CONTROL 15 - 16 Z107 16BK/DG GROUND 17 - 18 D64 20WT/LB CAN C BUS (-) 19 - 20 D465 20WT/GY DYNAMICS SENSOR HIGH DATA LINK 21 - 22 - 23 - 24 - 25 - 26 B7 20DG/VT RIGHT FRONT WHEEL SPEED SENSOR (+) 27 B6 20DG/WT RIGHT FRONT WHEEL SPEED SENSOR (-) 28 - 29 - 30 - 31 A107 12TN/RD FUSED B(+) 32 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 - 34 D464 20WT/OR DYNAMICS SENSOR LOW DATA LINK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 88 35 - 36 - 37 - 38 - 39 - 40 - 41 B3 20DG/YL REAR WHEEL SPEED SENSOR (-) 41 B22 20DG/YL REAR WHEEL SPEED SENSOR (-) 42 B4 20DG/GY REAR WHEEL SPEED SENSOR (+) 42 B222 20DG/WT REAR WHEEL SPEED SENSOR (+) 43 B2 20DG/LB RIGHT REAR WHEEL SPEED SENSOR (+) 44 B1 20DG/OR RIGHT REAR WHEEL SPEED SENSOR (-) 45 Z127 12BK/DG GROUND 46 - Component Location - 32 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 89 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Circuit Description 1 B222 18DG/WT REAR WHEEL SPEED SENSOR (+) 2 D65 18WT/LG CAN C BUS (+) 3 D64 18WT/LB CAN C BUS (-) 4 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 90 5 B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR (+) 6 Z107 16BK/DG GROUND 7 A111 16DG/RD FUSED B(+) 8 B22 18DG/YL REAR WHEEL SPEED SENSOR (-) 9-10 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR (-) 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 91 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 92 Electronic Brake Control Module: Diagrams Component ID: 201 Component : MODULE-ANTI-LOCK BRAKES Connector: Name : MODULE-ANTI-LOCK BRAKES Color : # of pins : 46 Qualifier : (AWAL) Pin Circuit Description 1-2 A111 16DG/RD FUSED B(+) 3 D65 20WT/LG CAN C BUS (+) 4-5-6-- 7-8-9-10 - 11 - 12 B9 20DG/LG LEFT FRONT WHEEL SPEED SENSOR (+) 13 B8 20DG/TN LEFT FRONT WHEEL SPEED SENSOR (-) 14 B401 20DG/BR TRAILER TOW DAMPING RELAY CONTROL 15 - 16 Z107 16BK/DG GROUND 17 - 18 D64 20WT/LB CAN C BUS (-) 19 - 20 D465 20WT/GY DYNAMICS SENSOR HIGH DATA LINK 21 - 22 - 23 - 24 - 25 - 26 B7 20DG/VT RIGHT FRONT WHEEL SPEED SENSOR (+) 27 B6 20DG/WT RIGHT FRONT WHEEL SPEED SENSOR (-) 28 - 29 - 30 - 31 A107 12TN/RD FUSED B(+) 32 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 - 34 D464 20WT/OR DYNAMICS SENSOR LOW DATA LINK Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 93 35 - 36 - 37 - 38 - 39 - 40 - 41 B3 20DG/YL REAR WHEEL SPEED SENSOR (-) 41 B22 20DG/YL REAR WHEEL SPEED SENSOR (-) 42 B4 20DG/GY REAR WHEEL SPEED SENSOR (+) 42 B222 20DG/WT REAR WHEEL SPEED SENSOR (+) 43 B2 20DG/LB RIGHT REAR WHEEL SPEED SENSOR (+) 44 B1 20DG/OR RIGHT REAR WHEEL SPEED SENSOR (-) 45 Z127 12BK/DG GROUND 46 - Component Location - 32 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 94 Connector: Name : MODULE-ANTI-LOCK BRAKES Color : BLACK # of pins : 14 Qualifier : (RWAL) Pin Circuit Description 1 B222 18DG/WT REAR WHEEL SPEED SENSOR (+) 2 D65 18WT/LG CAN C BUS (+) 3 D64 18WT/LB CAN C BUS (-) 4 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 95 5 B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR (+) 6 Z107 16BK/DG GROUND 7 A111 16DG/RD FUSED B(+) 8 B22 18DG/YL REAR WHEEL SPEED SENSOR (-) 9-10 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR (-) 11 - 12 - 13 - 14 - Component Location - 32 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 96 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description Electronic Brake Control Module: Description and Operation Description DESCRIPTION The Antilock Brake Module (ABM) (2) is mounted to the Hydraulic Control Unit (HCU) (3) and operates the ABS system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Description > Page 99 Electronic Brake Control Module: Description and Operation Operation OPERATION The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts. 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 102 Electronic Brake Control Module: Service and Repair Installation INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 Nm (16 in. lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Component ID: 83 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Circuit Description 1 K160 18BR/OR PWM FAN COIL SIGNAL Pin Circuit Description 1 K971 18BR/PK SENSOR GROUND 2 N210 18DB/DG FAN SPEED SENSOR SIGNAL 2 K916 18BR/OR SENSOR GROUND 3 K161 18BR/LB FAN SPEED SENSOR GROUND 3 N27 18DB/GY FAN SPEED SENSOR SIGNAL 4-5 K668 18BR 5 VOLT SUPPLY 5 F855 18PK/YL 5 VOLT SUPPLY 6 A212 18PK/YL FUSED B(+) 6 K161 18BR/LB FAN SPEED SENSOR GROUND Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 107 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 108 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 109 Radiator Cooling Fan Control Module: Diagrams Component ID: 83 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Circuit Description 1 K160 18BR/OR PWM FAN COIL SIGNAL Pin Circuit Description 1 K971 18BR/PK SENSOR GROUND 2 N210 18DB/DG FAN SPEED SENSOR SIGNAL 2 K916 18BR/OR SENSOR GROUND 3 K161 18BR/LB FAN SPEED SENSOR GROUND 3 N27 18DB/GY FAN SPEED SENSOR SIGNAL 4-5 K668 18BR 5 VOLT SUPPLY 5 F855 18PK/YL 5 VOLT SUPPLY 6 A212 18PK/YL FUSED B(+) 6 K161 18BR/LB FAN SPEED SENSOR GROUND Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 110 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 111 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 116 Horn Relay: Description and Operation Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 120 Parking Lamp Relay: Description and Operation Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 124 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 134 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 135 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 136 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 137 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 142 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 143 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 144 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 145 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Power Distribution Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 151 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 152 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 153 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 154 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start Condition NUMBER: 08-007-08 REV. A GROUP: Electrical DATE: July 04,2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH 04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART NUMBERS ARE AVAILABLE NOW. SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM / SKREEM OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred to as the Sentry Key Remote Entry Module (SKREEM). MODELS: 2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500) 2007 - 2008 (JK) Wrangler 2007 - 2008 (J1) Sebring (China) 2007 - 2008 (JS) Avenger/Sebring 2007 - 2008 (KA) Nitro 2008 (KK) Liberty/Cherokee 2007 - 2008 (MK) Compass/Patriot 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) Chrysler PT Cruiser NOTE: This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX). SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM), causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or cold weather conditions where a sufficient electrostatic charge is more easily produced. This condition is corrected by the replacement of the WCM. DIAGNOSIS: 1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the StarSCAN(R) scan tool to the vehicle. 2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R). 3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus". 4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and then reinstall the IOD fuse. 5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and run. 6. If the condition is temporarily corrected by performing the above steps, and if the part number of the WCM is earlier than the part number of the WCM listed in the part reference table in the Service Bulletin Parts Required Section below, then perform the Repair Procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 159 PARTS REQUIRED: NOTE: The part numbers listed in the following part reference table are to be used as A GUIDE to help determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to determine the correct WCM for the specific vehicle in question. In some earlier model years, the WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling (supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 160 REPAIR PROCEDURE: NOTE: If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail. NOTE: Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is being removed. 1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some International Markets), then the Shaft Lock Module will require replacement. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock > Removal and Installation. NOTE: The shaft lock module cannot be removed from the steering column while the locking bolt is in the locked position without irreversibly damaging the column. Before attempting service, the ignition key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave the key in the ignition lock cylinder until shaft lock module removal has been completed. If the steering wheel cannot be rotated, test and repair the wiring circuits between the module and the ignition switch as required. If no problem is found in these circuits, the module has failed with the locking bolt in the locked position and both the module and the steering column must be replaced with new units. 2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module, Sentry Key Remote Entry > Removal and Installation. NOTE: Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV. NOTE: If during the following steps the PIN number is properly entered but is rejected, then reenter the PIN number again until it is accepted. 3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the WCM/SKREEM as follows: a. Turn the ignition key to the ON position, (Engine Off) b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN position, (engine off). c. Select "ECU View." d. Scroll down and select "WCM" in the list of modules. e. Select "Misc. Functions." f. Scroll to "WCM Replaced." g. Press "Start". h. Press "Next". i. Select "Show Keyboard". j. Enter the vehicle PIN number. k. Select "Next". l. Verify PIN is correct. m. Select "Next". n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring (TPM) and so on. 0. Turn the ignition key to the OFF position. Wait 30 seconds. p. Turn the ignition key to the ON position, (Engine Off) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 161 q. Select "ECU View". r. Scroll down and select "WCM" in the list of modules. s. Select "Misc. Functions." t. Select "Program Ign. Keys" and follow on-screen prompts. u. Select "Complete". v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate. CAUTION: If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS model vehicles), then at least one (1 ignition key must have been programmed to the new WCM BEFORE the new Shaft Lock Module is "married" to the new WCM. 4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)? a. Yes >> Proceed to Step # 5. b. No >>Repair is complete. 5. Program the ELV as follows; a. Select "ECU View". b. Scroll down and select "WCM" in the list of modules. c. Select "Misc. Functions". d. Scroll to "ELV Replaced." e. Press "Start". f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from the ignition lock cylinder and listen for solenoid "click at lower end of column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 162 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 Power Distribution Module: Locations Component ID 199 Component ID: 199 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Circuit Description 1 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 2 T41 18YL/DB TRS T41 SIGNAL (P/N) 2 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 T752 20DG/OR STARTER SOLENOID CONTROL 3-4 K31 20BR FUEL PUMP CONTROL 5 W7 20BR/GY WIPER PARK SWITCH SENSE 6-7-8 G932 20VT/TN WASHER FLUID SWITCH RETURN 9 W1 20BR/TN WASHER FLUID SWITCH SENSE 10 T515 20YL/DB TRANSMISSION CONTROL 11 G70 20VT/LB HOOD AJAR SWITCH SENSE 12 - 13 - 14 - Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 165 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 166 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Circuit Description 1 K342 16BR/WT ASD CONTROL OUTPUT 2 A405 18RD/DB FUSED B(+) 3 A941 18RD FUSED B(+) 4-5 A104 20YL/RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 167 6 A310 16RD/LB FUSED B(+) 7 C15 14DB/WT REAR WINDOW DEFOGGER CONTROL OUTPUT 8 F12 14PK/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) 9 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 10 - 11 X22 18GY/LB HORN CONTROL OUTPUT 12 W3 18BR/WT WIPER LOW SPEED CONTROL OUTPUT 13 Z971 18BK GROUND 14 C16 18DB/GY HEATED MIRROR CONTROL OUTPUT 15 A212 20RD/OR FUSED B(+) 16 - - 17 A121 14RD/YL FUSED B(+) 18 A109 16OR/RD FUEL PUMP CONTROL OUTPUT 19 X21 18GY/YL HORN CONTROL OUTPUT 20 Z953 20BK GROUND 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 A400 14TN/RD FUSED B(+) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 168 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Circuit Description 1-2 W10 20BR WASHER PUMP MOTOR CONTROL 3 F20 20PK/WT IGNITION SWITCH OUTPUT (RUN-START) 4 A72 20RD/OR ADJUSTABLE PEDALS OUTPUT 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 169 6-7-8-9 G304 20VT/DB FRONT AXLE LOCK CONTROL 10 C13 20LB A/C CLUTCH CONTROL 10 C13 20LB/OR A/C CLUTCH CONTROL 11 K51 20BR/WT ASD CONTROL 12 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE 13 Z117 20BK/WT GROUND Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 170 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Circuit Description 1 A209 10RD FUSED B(+) 2-3 F984 18PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 4-5 F983 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 171 6 A205 18RD/OR FUSED B(+) 7-8 A944 20RD FUSED B(+) 9 A116 16YL/RD FUSED B(+) 10 A118 18RD/OR FUSED B(+) 11 - 12 A918 20RD FUSED B(+) 12 A918 16RD FUSED B(+) 13 F921 20PK/LB FUSED IGNITION SWITCH OUTPUT (RUN) 14 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 15 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 16 A930 16RD FUSED B(+) 17 F942 10PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 18 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT 19 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT 20 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 21 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 22 F12 14PK/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 172 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Circuit Description 1 Z118 16BK/YL GROUND 2 T102 16YL SHIFT MOTOR CONTROL A 3 T101 16DG SHIFT MOTOR CONTROL B 4-5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 173 6-7-8 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 9 T103 20YL/OR 5 VOLT SUPPLY 10 D201 20WT/DG MODE SENSOR A 11 G180 20VT/YL SENSOR RETURN 12 A880 20DB/RD FUSED B(+) 13 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 174 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Circuit Description 1 L61 20WT/LG LEFT FRONT TURN LAMP DRIVER 2 L60 20WT/TN RIGHT FRONT TURN LAMP DRIVER 3 L34 20WT/GY RIGHT HIGH BEAM DRIVER 4 L43 20WT/DB LEFT LOW BEAM DRIVER 5 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 175 6-7-8 G31 20VT/LG AAT SIGNAL 9 G930 20VT/TN AAT RETURN 10 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 176 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Circuit Description 1 D65 20WT/LG CAN C BUS (+) 2 D52 20WT/LB DIAGNOSTIC CAN C (+) 3 D55 20WT/OR CAN B BUS (+) 4 L63 20WT/DG LEFT REAR TURN LAMP DRIVER 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 177 6 L62 20WT/YL RIGHT REAR TURN LAMP DRIVER 7 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT 8-9 D64 20WT/LB CAN C BUS (-) 10 D51 20WT/BR DIAGNOSTIC CAN C (-) 11 D54 20WT CAN B BUS (-) 12 - 13 - 14 - 15 T70 20YL INPUT SPEED SENSOR 1 (N2) SIGNAL 16 T341 20DG/VT INPUT SPEED SENSOR 1 (N2) RETURN Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 178 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Circuit Description 1-2-3 L44 20WT/TN RIGHT LOW BEAM DRIVER 4 L33 20WT/LG LEFT HIGH BEAM DRIVER 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 179 6-7 C818 20LB/OR A/C PRESSURE 5 VOLT SUPPLY 8 L10 20WT/GY FUSED IGNITION SWITCH OUTPUT (RUN) 9-10 - 11 - 12 C18 20LB/BR A/C PRESSURE SIGNAL 13 C918 20BK/LB A/C PRESSURE GROUND 14 T751 20YL IGNITION START Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 180 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Circuit Description 1 A916 16RD FUSED B(+) Pin Circuit Description 1-2 A919 20RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 181 3 A106 20LB/RD FUSED B(+) 4 F201 20PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START) 5 F100 20PK/VT FUSED IGNITION SWITCH OUTPUT (RUN) 6 A100 14RD/VT FUSED B(+) 7 A210 12OR/RD FUSED B(+) 8 A940 18RD FUSED B(+) 9 A103 18GY/RD FUSED B(+) 10 L89 18WT/YL FOG LAMP CONTROL OUTPUT 11 L1 18WT/LG BACKUP LAMP FEED 12 A961 14RD FUEL HEATER CONTROL OUTPUT 12 C123 12LB/WT CONDENSER FAN CONTROL OUTPUT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 182 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Circuit Description 1 A111 16DG/RD FUSED B(+) 2 T750 14YL/GY STARTER MOTOR CONTROL OUTPUT 3 C3 20DB/YL A/C CLUTCH CONTROL OUTPUT 4 W4 16BR/OR WIPER MOTOR HIGH SPEED FEED 5 A114 18GY/RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 183 6 F30 10PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 7-8 L7 20WT/YL FUSED PARK LAMP FEED 9 L678 18BR FUSED PARK LAMP FEED 10 L70 20WT/GY FUSED PARK LAMP FEED 11 - 12 A107 12TN/RD FUSED B(+) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 184 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Circuit Description 1 A0 6RD B(+) Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 185 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 186 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Circuit Description 1 A11 8LB B(+) Pin Circuit Description 1 A0 6RD B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 187 Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 188 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 189 Power Distribution Module: Locations Component ID 215 Component ID: 215 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Circuit Description 1 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 2 T41 18YL/DB TRS T41 SIGNAL (P/N) 2 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 T752 20DG/OR STARTER SOLENOID CONTROL 3-4 K31 20BR FUEL PUMP CONTROL 5 W7 20BR/GY WIPER PARK SWITCH SENSE 6-7-8 G932 20VT/TN WASHER FLUID SWITCH RETURN 9 W1 20BR/TN WASHER FLUID SWITCH SENSE 10 T515 20YL/DB TRANSMISSION CONTROL 11 G70 20VT/LB HOOD AJAR SWITCH SENSE 12 - 13 - 14 - Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 190 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 191 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Circuit Description 1 K342 16BR/WT ASD CONTROL OUTPUT 2 A405 18RD/DB FUSED B(+) 3 A941 18RD FUSED B(+) 4-5 A104 20YL/RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 192 6 A310 16RD/LB FUSED B(+) 7 C15 14DB/WT REAR WINDOW DEFOGGER CONTROL OUTPUT 8 F12 14PK/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) 9 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 10 - 11 X22 18GY/LB HORN CONTROL OUTPUT 12 W3 18BR/WT WIPER LOW SPEED CONTROL OUTPUT 13 Z971 18BK GROUND 14 C16 18DB/GY HEATED MIRROR CONTROL OUTPUT 15 A212 20RD/OR FUSED B(+) 16 - - 17 A121 14RD/YL FUSED B(+) 18 A109 16OR/RD FUEL PUMP CONTROL OUTPUT 19 X21 18GY/YL HORN CONTROL OUTPUT 20 Z953 20BK GROUND 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 A400 14TN/RD FUSED B(+) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 193 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Circuit Description 1-2 W10 20BR WASHER PUMP MOTOR CONTROL 3 F20 20PK/WT IGNITION SWITCH OUTPUT (RUN-START) 4 A72 20RD/OR ADJUSTABLE PEDALS OUTPUT 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 194 6-7-8-9 G304 20VT/DB FRONT AXLE LOCK CONTROL 10 C13 20LB A/C CLUTCH CONTROL 10 C13 20LB/OR A/C CLUTCH CONTROL 11 K51 20BR/WT ASD CONTROL 12 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE 13 Z117 20BK/WT GROUND Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 195 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Circuit Description 1 A209 10RD FUSED B(+) 2-3 F984 18PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 4-5 F983 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 196 6 A205 18RD/OR FUSED B(+) 7-8 A944 20RD FUSED B(+) 9 A116 16YL/RD FUSED B(+) 10 A118 18RD/OR FUSED B(+) 11 - 12 A918 20RD FUSED B(+) 12 A918 16RD FUSED B(+) 13 F921 20PK/LB FUSED IGNITION SWITCH OUTPUT (RUN) 14 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 15 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 16 A930 16RD FUSED B(+) 17 F942 10PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 18 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT 19 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT 20 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 21 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 22 F12 14PK/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 197 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Circuit Description 1 Z118 16BK/YL GROUND 2 T102 16YL SHIFT MOTOR CONTROL A 3 T101 16DG SHIFT MOTOR CONTROL B 4-5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 198 6-7-8 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 9 T103 20YL/OR 5 VOLT SUPPLY 10 D201 20WT/DG MODE SENSOR A 11 G180 20VT/YL SENSOR RETURN 12 A880 20DB/RD FUSED B(+) 13 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 199 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Circuit Description 1 L61 20WT/LG LEFT FRONT TURN LAMP DRIVER 2 L60 20WT/TN RIGHT FRONT TURN LAMP DRIVER 3 L34 20WT/GY RIGHT HIGH BEAM DRIVER 4 L43 20WT/DB LEFT LOW BEAM DRIVER 5 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 200 6-7-8 G31 20VT/LG AAT SIGNAL 9 G930 20VT/TN AAT RETURN 10 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 201 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Circuit Description 1 D65 20WT/LG CAN C BUS (+) 2 D52 20WT/LB DIAGNOSTIC CAN C (+) 3 D55 20WT/OR CAN B BUS (+) 4 L63 20WT/DG LEFT REAR TURN LAMP DRIVER 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 202 6 L62 20WT/YL RIGHT REAR TURN LAMP DRIVER 7 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT 8-9 D64 20WT/LB CAN C BUS (-) 10 D51 20WT/BR DIAGNOSTIC CAN C (-) 11 D54 20WT CAN B BUS (-) 12 - 13 - 14 - 15 T70 20YL INPUT SPEED SENSOR 1 (N2) SIGNAL 16 T341 20DG/VT INPUT SPEED SENSOR 1 (N2) RETURN Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 203 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Circuit Description 1-2-3 L44 20WT/TN RIGHT LOW BEAM DRIVER 4 L33 20WT/LG LEFT HIGH BEAM DRIVER 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 204 6-7 C818 20LB/OR A/C PRESSURE 5 VOLT SUPPLY 8 L10 20WT/GY FUSED IGNITION SWITCH OUTPUT (RUN) 9-10 - 11 - 12 C18 20LB/BR A/C PRESSURE SIGNAL 13 C918 20BK/LB A/C PRESSURE GROUND 14 T751 20YL IGNITION START Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 205 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Circuit Description 1 A916 16RD FUSED B(+) Pin Circuit Description 1-2 A919 20RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 206 3 A106 20LB/RD FUSED B(+) 4 F201 20PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START) 5 F100 20PK/VT FUSED IGNITION SWITCH OUTPUT (RUN) 6 A100 14RD/VT FUSED B(+) 7 A210 12OR/RD FUSED B(+) 8 A940 18RD FUSED B(+) 9 A103 18GY/RD FUSED B(+) 10 L89 18WT/YL FOG LAMP CONTROL OUTPUT 11 L1 18WT/LG BACKUP LAMP FEED 12 A961 14RD FUEL HEATER CONTROL OUTPUT 12 C123 12LB/WT CONDENSER FAN CONTROL OUTPUT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 207 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Circuit Description 1 A111 16DG/RD FUSED B(+) 2 T750 14YL/GY STARTER MOTOR CONTROL OUTPUT 3 C3 20DB/YL A/C CLUTCH CONTROL OUTPUT 4 W4 16BR/OR WIPER MOTOR HIGH SPEED FEED 5 A114 18GY/RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 208 6 F30 10PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 7-8 L7 20WT/YL FUSED PARK LAMP FEED 9 L678 18BR FUSED PARK LAMP FEED 10 L70 20WT/GY FUSED PARK LAMP FEED 11 - 12 A107 12TN/RD FUSED B(+) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 209 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Circuit Description 1 A0 6RD B(+) Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 210 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 211 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Circuit Description 1 A11 8LB B(+) Pin Circuit Description 1 A0 6RD B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 212 Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component ID 199 > Page 213 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 Power Distribution Module: Diagrams Component ID 199 Component ID: 199 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Circuit Description 1 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 2 T41 18YL/DB TRS T41 SIGNAL (P/N) 2 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 T752 20DG/OR STARTER SOLENOID CONTROL 3-4 K31 20BR FUEL PUMP CONTROL 5 W7 20BR/GY WIPER PARK SWITCH SENSE 6-7-8 G932 20VT/TN WASHER FLUID SWITCH RETURN 9 W1 20BR/TN WASHER FLUID SWITCH SENSE 10 T515 20YL/DB TRANSMISSION CONTROL 11 G70 20VT/LB HOOD AJAR SWITCH SENSE 12 - 13 - 14 - Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 216 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 217 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Circuit Description 1 K342 16BR/WT ASD CONTROL OUTPUT 2 A405 18RD/DB FUSED B(+) 3 A941 18RD FUSED B(+) 4-5 A104 20YL/RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 218 6 A310 16RD/LB FUSED B(+) 7 C15 14DB/WT REAR WINDOW DEFOGGER CONTROL OUTPUT 8 F12 14PK/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) 9 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 10 - 11 X22 18GY/LB HORN CONTROL OUTPUT 12 W3 18BR/WT WIPER LOW SPEED CONTROL OUTPUT 13 Z971 18BK GROUND 14 C16 18DB/GY HEATED MIRROR CONTROL OUTPUT 15 A212 20RD/OR FUSED B(+) 16 - - 17 A121 14RD/YL FUSED B(+) 18 A109 16OR/RD FUEL PUMP CONTROL OUTPUT 19 X21 18GY/YL HORN CONTROL OUTPUT 20 Z953 20BK GROUND 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 A400 14TN/RD FUSED B(+) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 219 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Circuit Description 1-2 W10 20BR WASHER PUMP MOTOR CONTROL 3 F20 20PK/WT IGNITION SWITCH OUTPUT (RUN-START) 4 A72 20RD/OR ADJUSTABLE PEDALS OUTPUT 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 220 6-7-8-9 G304 20VT/DB FRONT AXLE LOCK CONTROL 10 C13 20LB A/C CLUTCH CONTROL 10 C13 20LB/OR A/C CLUTCH CONTROL 11 K51 20BR/WT ASD CONTROL 12 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE 13 Z117 20BK/WT GROUND Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 221 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Circuit Description 1 A209 10RD FUSED B(+) 2-3 F984 18PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 4-5 F983 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 222 6 A205 18RD/OR FUSED B(+) 7-8 A944 20RD FUSED B(+) 9 A116 16YL/RD FUSED B(+) 10 A118 18RD/OR FUSED B(+) 11 - 12 A918 20RD FUSED B(+) 12 A918 16RD FUSED B(+) 13 F921 20PK/LB FUSED IGNITION SWITCH OUTPUT (RUN) 14 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 15 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 16 A930 16RD FUSED B(+) 17 F942 10PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 18 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT 19 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT 20 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 21 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 22 F12 14PK/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 223 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Circuit Description 1 Z118 16BK/YL GROUND 2 T102 16YL SHIFT MOTOR CONTROL A 3 T101 16DG SHIFT MOTOR CONTROL B 4-5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 224 6-7-8 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 9 T103 20YL/OR 5 VOLT SUPPLY 10 D201 20WT/DG MODE SENSOR A 11 G180 20VT/YL SENSOR RETURN 12 A880 20DB/RD FUSED B(+) 13 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 225 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Circuit Description 1 L61 20WT/LG LEFT FRONT TURN LAMP DRIVER 2 L60 20WT/TN RIGHT FRONT TURN LAMP DRIVER 3 L34 20WT/GY RIGHT HIGH BEAM DRIVER 4 L43 20WT/DB LEFT LOW BEAM DRIVER 5 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 226 6-7-8 G31 20VT/LG AAT SIGNAL 9 G930 20VT/TN AAT RETURN 10 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 227 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Circuit Description 1 D65 20WT/LG CAN C BUS (+) 2 D52 20WT/LB DIAGNOSTIC CAN C (+) 3 D55 20WT/OR CAN B BUS (+) 4 L63 20WT/DG LEFT REAR TURN LAMP DRIVER 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 228 6 L62 20WT/YL RIGHT REAR TURN LAMP DRIVER 7 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT 8-9 D64 20WT/LB CAN C BUS (-) 10 D51 20WT/BR DIAGNOSTIC CAN C (-) 11 D54 20WT CAN B BUS (-) 12 - 13 - 14 - 15 T70 20YL INPUT SPEED SENSOR 1 (N2) SIGNAL 16 T341 20DG/VT INPUT SPEED SENSOR 1 (N2) RETURN Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 229 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Circuit Description 1-2-3 L44 20WT/TN RIGHT LOW BEAM DRIVER 4 L33 20WT/LG LEFT HIGH BEAM DRIVER 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 230 6-7 C818 20LB/OR A/C PRESSURE 5 VOLT SUPPLY 8 L10 20WT/GY FUSED IGNITION SWITCH OUTPUT (RUN) 9-10 - 11 - 12 C18 20LB/BR A/C PRESSURE SIGNAL 13 C918 20BK/LB A/C PRESSURE GROUND 14 T751 20YL IGNITION START Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 231 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Circuit Description 1 A916 16RD FUSED B(+) Pin Circuit Description 1-2 A919 20RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 232 3 A106 20LB/RD FUSED B(+) 4 F201 20PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START) 5 F100 20PK/VT FUSED IGNITION SWITCH OUTPUT (RUN) 6 A100 14RD/VT FUSED B(+) 7 A210 12OR/RD FUSED B(+) 8 A940 18RD FUSED B(+) 9 A103 18GY/RD FUSED B(+) 10 L89 18WT/YL FOG LAMP CONTROL OUTPUT 11 L1 18WT/LG BACKUP LAMP FEED 12 A961 14RD FUEL HEATER CONTROL OUTPUT 12 C123 12LB/WT CONDENSER FAN CONTROL OUTPUT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 233 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Circuit Description 1 A111 16DG/RD FUSED B(+) 2 T750 14YL/GY STARTER MOTOR CONTROL OUTPUT 3 C3 20DB/YL A/C CLUTCH CONTROL OUTPUT 4 W4 16BR/OR WIPER MOTOR HIGH SPEED FEED 5 A114 18GY/RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 234 6 F30 10PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 7-8 L7 20WT/YL FUSED PARK LAMP FEED 9 L678 18BR FUSED PARK LAMP FEED 10 L70 20WT/GY FUSED PARK LAMP FEED 11 - 12 A107 12TN/RD FUSED B(+) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 235 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Circuit Description 1 A0 6RD B(+) Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 236 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 237 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Circuit Description 1 A11 8LB B(+) Pin Circuit Description 1 A0 6RD B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 238 Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 239 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 240 Power Distribution Module: Diagrams Component ID 215 Component ID: 215 Component : MODULE-TOTALLY INTEGRATED POWER Connector: Name : MODULE-TOTALLY INTEGRATED POWER C1 Color : LT. GRAY # of pins : 14 Pin Circuit Description 1 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 2 T41 18YL/DB TRS T41 SIGNAL (P/N) 2 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 T752 20DG/OR STARTER SOLENOID CONTROL 3-4 K31 20BR FUEL PUMP CONTROL 5 W7 20BR/GY WIPER PARK SWITCH SENSE 6-7-8 G932 20VT/TN WASHER FLUID SWITCH RETURN 9 W1 20BR/TN WASHER FLUID SWITCH SENSE 10 T515 20YL/DB TRANSMISSION CONTROL 11 G70 20VT/LB HOOD AJAR SWITCH SENSE 12 - 13 - 14 - Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 241 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 242 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C10 Color : LT. GRAY # of pins : 22 Pin Circuit Description 1 K342 16BR/WT ASD CONTROL OUTPUT 2 A405 18RD/DB FUSED B(+) 3 A941 18RD FUSED B(+) 4-5 A104 20YL/RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 243 6 A310 16RD/LB FUSED B(+) 7 C15 14DB/WT REAR WINDOW DEFOGGER CONTROL OUTPUT 8 F12 14PK/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) 9 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 10 - 11 X22 18GY/LB HORN CONTROL OUTPUT 12 W3 18BR/WT WIPER LOW SPEED CONTROL OUTPUT 13 Z971 18BK GROUND 14 C16 18DB/GY HEATED MIRROR CONTROL OUTPUT 15 A212 20RD/OR FUSED B(+) 16 - - 17 A121 14RD/YL FUSED B(+) 18 A109 16OR/RD FUEL PUMP CONTROL OUTPUT 19 X21 18GY/YL HORN CONTROL OUTPUT 20 Z953 20BK GROUND 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 A400 14TN/RD FUSED B(+) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 244 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C2 Color : BLACK # of pins : 13 Pin Circuit Description 1-2 W10 20BR WASHER PUMP MOTOR CONTROL 3 F20 20PK/WT IGNITION SWITCH OUTPUT (RUN-START) 4 A72 20RD/OR ADJUSTABLE PEDALS OUTPUT 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 245 6-7-8-9 G304 20VT/DB FRONT AXLE LOCK CONTROL 10 C13 20LB A/C CLUTCH CONTROL 10 C13 20LB/OR A/C CLUTCH CONTROL 11 K51 20BR/WT ASD CONTROL 12 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE 13 Z117 20BK/WT GROUND Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 246 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C3 Color : BLACK # of pins : 22 Pin Circuit Description 1 A209 10RD FUSED B(+) 2-3 F984 18PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 4-5 F983 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 247 6 A205 18RD/OR FUSED B(+) 7-8 A944 20RD FUSED B(+) 9 A116 16YL/RD FUSED B(+) 10 A118 18RD/OR FUSED B(+) 11 - 12 A918 20RD FUSED B(+) 12 A918 16RD FUSED B(+) 13 F921 20PK/LB FUSED IGNITION SWITCH OUTPUT (RUN) 14 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 15 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 16 A930 16RD FUSED B(+) 17 F942 10PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 18 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT 19 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT 20 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 21 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 22 F12 14PK/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 248 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C4 Color : LT. GRAY # of pins : 13 Pin Circuit Description 1 Z118 16BK/YL GROUND 2 T102 16YL SHIFT MOTOR CONTROL A 3 T101 16DG SHIFT MOTOR CONTROL B 4-5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 249 6-7-8 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 9 T103 20YL/OR 5 VOLT SUPPLY 10 D201 20WT/DG MODE SENSOR A 11 G180 20VT/YL SENSOR RETURN 12 A880 20DB/RD FUSED B(+) 13 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 250 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C5 Color : BLACK # of pins : 10 Pin Circuit Description 1 L61 20WT/LG LEFT FRONT TURN LAMP DRIVER 2 L60 20WT/TN RIGHT FRONT TURN LAMP DRIVER 3 L34 20WT/GY RIGHT HIGH BEAM DRIVER 4 L43 20WT/DB LEFT LOW BEAM DRIVER 5 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 251 6-7-8 G31 20VT/LG AAT SIGNAL 9 G930 20VT/TN AAT RETURN 10 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 252 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C6 Color : BROWN # of pins : 16 Pin Circuit Description 1 D65 20WT/LG CAN C BUS (+) 2 D52 20WT/LB DIAGNOSTIC CAN C (+) 3 D55 20WT/OR CAN B BUS (+) 4 L63 20WT/DG LEFT REAR TURN LAMP DRIVER 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 253 6 L62 20WT/YL RIGHT REAR TURN LAMP DRIVER 7 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT 8-9 D64 20WT/LB CAN C BUS (-) 10 D51 20WT/BR DIAGNOSTIC CAN C (-) 11 D54 20WT CAN B BUS (-) 12 - 13 - 14 - 15 T70 20YL INPUT SPEED SENSOR 1 (N2) SIGNAL 16 T341 20DG/VT INPUT SPEED SENSOR 1 (N2) RETURN Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 254 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C7 Color : BLUE # of pins : 14 Pin Circuit Description 1-2-3 L44 20WT/TN RIGHT LOW BEAM DRIVER 4 L33 20WT/LG LEFT HIGH BEAM DRIVER 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 255 6-7 C818 20LB/OR A/C PRESSURE 5 VOLT SUPPLY 8 L10 20WT/GY FUSED IGNITION SWITCH OUTPUT (RUN) 9-10 - 11 - 12 C18 20LB/BR A/C PRESSURE SIGNAL 13 C918 20BK/LB A/C PRESSURE GROUND 14 T751 20YL IGNITION START Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 256 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C8 Color : LT. GRAY # of pins : 12 Pin Circuit Description 1 A916 16RD FUSED B(+) Pin Circuit Description 1-2 A919 20RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 257 3 A106 20LB/RD FUSED B(+) 4 F201 20PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START) 5 F100 20PK/VT FUSED IGNITION SWITCH OUTPUT (RUN) 6 A100 14RD/VT FUSED B(+) 7 A210 12OR/RD FUSED B(+) 8 A940 18RD FUSED B(+) 9 A103 18GY/RD FUSED B(+) 10 L89 18WT/YL FOG LAMP CONTROL OUTPUT 11 L1 18WT/LG BACKUP LAMP FEED 12 A961 14RD FUEL HEATER CONTROL OUTPUT 12 C123 12LB/WT CONDENSER FAN CONTROL OUTPUT Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 258 Connector: Name : MODULE-TOTALLY INTEGRATED POWER C9 Color : BLACK # of pins : 12 Pin Circuit Description 1 A111 16DG/RD FUSED B(+) 2 T750 14YL/GY STARTER MOTOR CONTROL OUTPUT 3 C3 20DB/YL A/C CLUTCH CONTROL OUTPUT 4 W4 16BR/OR WIPER MOTOR HIGH SPEED FEED 5 A114 18GY/RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 259 6 F30 10PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 7-8 L7 20WT/YL FUSED PARK LAMP FEED 9 L678 18BR FUSED PARK LAMP FEED 10 L70 20WT/GY FUSED PARK LAMP FEED 11 - 12 A107 12TN/RD FUSED B(+) Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 260 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (DIESEL) Pin Circuit Description 1 A0 6RD B(+) Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 261 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 262 Connector: Name : MODULE-TOTALLY INTEGRATED POWER-EYELET Color : # of pins : 1 Qualifier : (GAS) Pin Circuit Description 1 A11 8LB B(+) Pin Circuit Description 1 A0 6RD B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 263 Component Location - 33 Component Location - 34 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Component ID 199 > Page 264 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description Power Distribution Module: Description and Operation Description DESCRIPTION The Totally Integrated Power Module (2)(TIPM) is a combination unit that performs the functions of the Power Distribution Center (PDC) and the Front Control Module. The TIPM is a printed circuit board based module that contains fuses, internal relays and a microprocessor that performs the functions previously executed by the FCM. The TIPM (2) is located in the engine compartment, next to the battery (1) and connects directly to the B+ cable (5) via a stud located on top of the unit. The ground connection is via electrical connectors. The TIPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic TIPM housing includes a base and cover. The TIPM cover is easily opened or removed for service and has a fuse and relay layout map integral to the inside surface of the cover. The TIPM housing base and cover are secured in place via mounting tabs. The mounting tabs secure the TIPM (2) to the battery tray mounting bracket (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Description > Page 267 Power Distribution Module: Description and Operation Operation OPERATION All of the current from the battery and the generator output enters the Totally Integrated Power Module (TIPM) via a stud on the top of the module. The TIPM cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For a complete wiring diagram Refer to Diagrams/Electrical. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal Power Distribution Module: Service and Repair Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the B+ terminal nut (6) from the Totally Integrated Power Module (2)(TIPM) B+ terminal. Remove the B+ cable (5) from the TIPM (2). 3. Using a suitable flat blade tool, disengage the TIPM (2) upper retaining tabs from the battery tray bracket (3). 4. Grasp the TIPM (1) and rotate the assembly up to free it from its mounting bracket (3). Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 5. Disconnect the electrical connectors (2) by depressing the locking tab and rotating the connector arm outboard, until the connector is free from the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 270 TIPM assembly (1). Be certain to pull the connectors straight off. 6. Remove the TIPM (1) from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 271 Power Distribution Module: Service and Repair Installation INSTALLATION 1. Position the Totally Integrated Power Module (1)(TIPM) into the vehicle. NOTE: Totally Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors (2) by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the TIPM assembly (1). 3. Turn the TIPM (1) so that the connector side is facing down. Install the assembly onto the TIPM battery tray bracket (3) making sure to line up the lower retaining tab with the retaining slot in the tray (1). 4. Push the TIPM (1) downward to lock the upper retaining clips into the bracket (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Removal > Page 272 5. Install the B+ terminal cable (5) and nut (6) on the B+ terminal of the TIPM (2). 6. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel Relay Box: Locations Fuses (Integrated Power Module) - Diesel FUSES (INTEGRATED POWER MODULE) - DIESEL An integrated Power Module is located in the engine compartment near the battery. This center contains cartridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Underhood Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 277 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 278 CAUTION: - When installing the Integrated Power Module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 279 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 280 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel Relay Box: Application and ID Fuses (Integrated Power Module) - Diesel FUSES (INTEGRATED POWER MODULE) - DIESEL An integrated Power Module is located in the engine compartment near the battery. This center contains cartridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Underhood Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 283 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 284 CAUTION: - When installing the Integrated Power Module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 285 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 286 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 294 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 295 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 296 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 297 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 298 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 299 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 300 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 301 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 302 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 303 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 304 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 306 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 307 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 308 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 317 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 318 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 319 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 320 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 321 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 322 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 323 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 329 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 330 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 331 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 332 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 338 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 339 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 340 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 341 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 346 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 347 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 348 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 349 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 350 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 351 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 352 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 358 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 359 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 360 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 361 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 367 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 368 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 369 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 370 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 371 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 372 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 373 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 205 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Circuit Description 1 K139 18DB WASTEGATE SOLENOID CONTROL 2 G6 18VT/GY OIL PRESSURE SIGNAL 3-4 D65 18WT/LG CAN C BUS (+) 5 D64 18WT/LB CAN C BUS (-) 6 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 7 K20 18BR/GY GEN FIELD CONTROL 8 K314 18TN/YL TTVA MOTOR (+) 9-10 - 11 K923 18BR/WT WATER IN FUEL SENSOR GROUND 12 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 13 K615 18VT/WT INLET AIR TEMPERATURE SENSE 14 - 15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 K616 18BR/YL INLET AIR PRESSURE SENSE 17 K2 18VT/OR ECT SIGNAL 18 - 19 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER 20 K315 18TN/OR TTVA MOTOR (-) 21 K161 18BR/LB FAN SPEED SENSOR GROUND 22 K24 18BR/LB CKP SIGNAL 23 K200 18BR/YL SENSOR GROUND 24 K44 18DB/GY CMP SIGNAL 25 K668 18BR 5 VOLT SUPPLY 26 - 27 K853 18DB/BR 5 VOLT SUPPLY 28 - 29 K690 18BR/YL SENSOR GROUND 30 K11 16BR/YL INJECTOR CONTROL NO. 1 31 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 32 K944 18BK/GY CMP SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 376 33 K167 18BR/YL APPS NO. 1 RETURN 34 N210 18DB/DG FAN SPEED SENSOR SIGNAL 35 - 36 K14 16BR/TN INJECTOR CONTROL NO. 4 37 - 38 - 39 - 40 K13 16TN INJECTOR CONTROL NO. 3 41 K210 18DB/TN SENSOR GROUND 42 K852 18BR/VT 5 VOLT SUPPLY 43 K37 18LB BOOST PRESSURE SENSOR SIGNAL 44 - 45 - 46 K58 16BR/VT INJECTOR CONTROL NO. 6 47 - 48 - 49 - 50 K12 16BR/DB INJECTOR CONTROL NO. 2 51 - 52 K975 18BR/OR CKP SENSOR GROUND 53 K915 18BR/WT FUEL RAIL SENSOR RETURN 54 F855 18PK/YL 5 VOLT SUPPLY 55 - 56 K38 16GY INJECTOR CONTROL NO. 5 57 K229 16TN/PK INJECTOR HIGH SIDE DRIVER-BANK 2 58 - 59 K227 16BR/LG INJECTOR HIGH SIDE DRIVER-BANK 1 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 377 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 378 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 379 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K682 18DB/WT EGR CONTROL NO. 1 3 K684 18DB/YL EGR CONTROL NO. 2 4 K686 18GY/DB EGR CONTROL NO. 3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 380 5 K685 18DB EGR SIGNAL NO. 2 6-7 K161 18BR/LB FAN SPEED SENSOR GROUND 8-9 K670 18BR/LB EGR BYPASS VALVE SIGNAL 10 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN 11 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 12 - 13 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 14 K926 18DB/GY CRANKCASE SENSOR SIGNAL 15 K2 18VT/OR ECT SIGNAL 16 - 17 K671 18BR/DB EGR BYPASS STATUS 18 N27 18DB/GY FAN SPEED SENSOR SIGNAL 19 K37 18BR BOOST PRESSURE SENSOR SIGNAL 20 K616 18BR/YL INLET AIR PRESSURE SENSE 21 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 22 K971 18BR/PK SENSOR GROUND 23 - 24 K615 18VT/WT INLET AIR TEMPERATURE SENSE 25 K683 18DB/GY EGR SIGNAL NO. 1 26 K824 18DB/BR 5 VOLT SUPPLY 27 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 28 A804 18RD GEN SENSE 29 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 30 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 31 K24 18BR/LB CKP SIGNAL 32 G6 18VT/GY OIL PRESSURE SIGNAL 33 K972 18DB/TN ACTUATOR GROUND 34 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 35 K687 18DB/LB EGR SIGNAL NO. 3 36 F855 18PK/YL 5 VOLT SUPPLY 37 K44 18DB/GY CMP SIGNAL 38 D130 18BR/VT ACTUATOR HIGH DATA LINK 39 D131 18WT/LG ACTUATOR LOW DATA LINK 40 K20 18BR/GY GEN FIELD CONTROL 41 K935 18DB EGR TEMPERATURE SENSOR SIGNAL 42 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 43 K541 18BR/VT TURBO SPEED SENSOR GROUND 44 K925 18BR/OR CKP SENSOR GROUND 45 K58 16BR/VT INJECTOR CONTROL NO. 6 46 K12 16BR/DB INJECTOR CONTROL NO. 2 47 K914 18BR/WT SENSOR GROUND 48 K916 18BR/OR SENSOR GROUND 49 - 50 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL 51 K613 16GY/BR INJECTOR HIGH SIDE DRIVER NO. 3 52 K612 16YL/BR INJECTOR HIGH SIDE DRIVER NO. 2 53 K611 16OR/BR INJECTOR HIGH SIDE DRIVER NO. 1 54 K14 16BR/TN INJECTOR CONTROL NO. 4 55 K38 16GY INJECTOR CONTROL NO. 5 56 K13 16TN INJECTOR CONTROL NO. 3 57 K11 16BR/YL INJECTOR CONTROL NO. 1 58 K658 16LG/BR INJECTOR HIGH SIDE DRIVER NO. 6 59 K638 16LB/BR INJECTOR HIGH SIDE DRIVER NO. 5 60 K614 16WT/BR INJECTOR HIGH SIDE DRIVER NO. 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 381 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 382 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 383 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Circuit Description 1-2-3 K23 18BR/WT APPS NO. 1 SIGNAL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 384 5 T515 18YL/DB TRANSMISSION CONTROL 6 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 7 K31 18BR FUEL PUMP CONTROL 8-9 T41 18YL/DB TRS T41 SIGNAL (P/N) 10 - 11 - 12 - 13 T6 18DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 14 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 15 T9 18DG/TN 3-4 SOLENOID CONTROL 16 - 17 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 18 - 19 - 20 A209 16RD FUSED B(+) 21 Z902 16BK GROUND 22 - 23 F856 18YL/PK 5 VOLT SUPPLY 24 K900 18DB/DG SENSOR GROUND 25 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 26 - 27 K312 18OR TTVA POSITION SENSOR SIGNAL 28 - 29 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL 30 A209 16RD FUSED B(+) 31 - 32 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 K854 18VT/BR 5 VOLT SUPPLY 34 - 35 K29 18WT/BR APPS NO. 2 SIGNAL 36 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 37 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 38 - 39 - 40 A209 16RD FUSED B(+) 41 C13 18LB/OR A/C CLUTCH CONTROL 42 - 43 K160 18BR/OR PWM FAN COIL SIGNAL 44 T14 18DG/BR OUTPUT SPEED SIGNAL 45 T13 18DG/VT SPEED SENSOR GROUND 46 V37 18VT S/C SWITCH NO. 1 SIGNAL 47 K25 18DB/VT BATT TEMP SIGNAL 48 K400 18BR/VT APPS NO. 2 RETURN 49 Z902 16BK GROUND 50 Z902 16BK GROUND Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 385 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 386 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 387 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 D65 18WT/LG CAN C BUS (+) 2 K31 18BR FUEL PUMP CONTROL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 388 5 G905 18BR/OR EXHAUST BRAKE SWITCH SIGNAL 6 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 7 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 8 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 9 K186 18BR/OR EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 10 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 11 - 12 - 13 - 14 - 15 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 16 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 17 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 18 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 19 - 20 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 21 D64 18WT/LB CAN C BUS (-) 22 K400 18BR/VT APPS NO. 2 RETURN 23 - 24 K29 18WT/BR APPS NO. 2 SIGNAL 25 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 26 K854 18VT/BR 5 VOLT SUPPLY 27 K852 18BR/LB 5 VOLT SUPPLY 28 K167 18BR/DG APPS NO. 1 RETURN 29 K900 18DB/DG SENSOR GROUND 30 K25 18DB/VT BATT TEMP SIGNAL 31 D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK 32 - 33 V937 18VT/BR S/C SWITCH RETURN 34 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 35 K23 18BR/WT APPS NO. 1 SIGNAL 36 - - 37 K128 18DG/LG REMOTE THROTTLE SIGNAL 38 - 39 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 40 V37 18VT S/C SWITCH NO. 1 SIGNAL 41 - 42 - 43 K348 18BR SMART POWER RELAY RETURN 44 C13 18LB A/C CLUTCH CONTROL 45 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 46 - 47 Z902 16BK GROUND 48 Z902 16BK GROUND 49 A209 16RD FUSED B(+) 50 A209 16RD FUSED B(+) 51 D132 18WT DIAGNOSTIC PORT LOW DATA LINK 52 - 53 - 54 G904 18VT/DG EXHAUST BRAKE LAMP SIGNAL 55 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 56 V38 18VT/OR S/C SWITCH NO. 2 SIGNAL 57 Z902 16BK GROUND 58 - 59 - 60 A209 16RD FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 389 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 390 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 391 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 392 Engine Control Module: Locations Module-Powertrain Control Component ID 198 Component ID: 198 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 12345- 6789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 393 18 - - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 394 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 395 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 396 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 397 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 398 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 399 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 400 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 401 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 402 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 403 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 404 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 405 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 406 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 407 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 408 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 409 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 410 Component ID 211 Component ID: 211 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 411 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 - 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 412 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 413 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 414 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 415 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 416 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 417 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 418 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 419 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 420 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 421 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 422 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 423 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 424 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 425 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 426 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 427 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 428 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 431 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 432 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 433 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 434 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 435 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 436 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 437 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 438 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 439 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 440 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 441 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 442 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 443 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 444 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 445 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 446 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 447 Engine Control Module: Connector Views Module-Engine Control Component ID: 205 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Circuit Description 1 K139 18DB WASTEGATE SOLENOID CONTROL 2 G6 18VT/GY OIL PRESSURE SIGNAL 3-4 D65 18WT/LG CAN C BUS (+) 5 D64 18WT/LB CAN C BUS (-) 6 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 7 K20 18BR/GY GEN FIELD CONTROL 8 K314 18TN/YL TTVA MOTOR (+) 9-10 - 11 K923 18BR/WT WATER IN FUEL SENSOR GROUND 12 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 13 K615 18VT/WT INLET AIR TEMPERATURE SENSE 14 - 15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 K616 18BR/YL INLET AIR PRESSURE SENSE 17 K2 18VT/OR ECT SIGNAL 18 - 19 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER 20 K315 18TN/OR TTVA MOTOR (-) 21 K161 18BR/LB FAN SPEED SENSOR GROUND 22 K24 18BR/LB CKP SIGNAL 23 K200 18BR/YL SENSOR GROUND 24 K44 18DB/GY CMP SIGNAL 25 K668 18BR 5 VOLT SUPPLY 26 - 27 K853 18DB/BR 5 VOLT SUPPLY 28 - 29 K690 18BR/YL SENSOR GROUND 30 K11 16BR/YL INJECTOR CONTROL NO. 1 31 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 448 32 K944 18BK/GY CMP SENSOR GROUND 33 K167 18BR/YL APPS NO. 1 RETURN 34 N210 18DB/DG FAN SPEED SENSOR SIGNAL 35 - 36 K14 16BR/TN INJECTOR CONTROL NO. 4 37 - 38 - 39 - 40 K13 16TN INJECTOR CONTROL NO. 3 41 K210 18DB/TN SENSOR GROUND 42 K852 18BR/VT 5 VOLT SUPPLY 43 K37 18LB BOOST PRESSURE SENSOR SIGNAL 44 - 45 - 46 K58 16BR/VT INJECTOR CONTROL NO. 6 47 - 48 - 49 - 50 K12 16BR/DB INJECTOR CONTROL NO. 2 51 - 52 K975 18BR/OR CKP SENSOR GROUND 53 K915 18BR/WT FUEL RAIL SENSOR RETURN 54 F855 18PK/YL 5 VOLT SUPPLY 55 - 56 K38 16GY INJECTOR CONTROL NO. 5 57 K229 16TN/PK INJECTOR HIGH SIDE DRIVER-BANK 2 58 - 59 K227 16BR/LG INJECTOR HIGH SIDE DRIVER-BANK 1 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 449 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 450 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 451 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K682 18DB/WT EGR CONTROL NO. 1 3 K684 18DB/YL EGR CONTROL NO. 2 4 K686 18GY/DB EGR CONTROL NO. 3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 452 5 K685 18DB EGR SIGNAL NO. 2 6-7 K161 18BR/LB FAN SPEED SENSOR GROUND 8-9 K670 18BR/LB EGR BYPASS VALVE SIGNAL 10 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN 11 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 12 - 13 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 14 K926 18DB/GY CRANKCASE SENSOR SIGNAL 15 K2 18VT/OR ECT SIGNAL 16 - 17 K671 18BR/DB EGR BYPASS STATUS 18 N27 18DB/GY FAN SPEED SENSOR SIGNAL 19 K37 18BR BOOST PRESSURE SENSOR SIGNAL 20 K616 18BR/YL INLET AIR PRESSURE SENSE 21 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 22 K971 18BR/PK SENSOR GROUND 23 - 24 K615 18VT/WT INLET AIR TEMPERATURE SENSE 25 K683 18DB/GY EGR SIGNAL NO. 1 26 K824 18DB/BR 5 VOLT SUPPLY 27 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 28 A804 18RD GEN SENSE 29 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 30 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 31 K24 18BR/LB CKP SIGNAL 32 G6 18VT/GY OIL PRESSURE SIGNAL 33 K972 18DB/TN ACTUATOR GROUND 34 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 35 K687 18DB/LB EGR SIGNAL NO. 3 36 F855 18PK/YL 5 VOLT SUPPLY 37 K44 18DB/GY CMP SIGNAL 38 D130 18BR/VT ACTUATOR HIGH DATA LINK 39 D131 18WT/LG ACTUATOR LOW DATA LINK 40 K20 18BR/GY GEN FIELD CONTROL 41 K935 18DB EGR TEMPERATURE SENSOR SIGNAL 42 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 43 K541 18BR/VT TURBO SPEED SENSOR GROUND 44 K925 18BR/OR CKP SENSOR GROUND 45 K58 16BR/VT INJECTOR CONTROL NO. 6 46 K12 16BR/DB INJECTOR CONTROL NO. 2 47 K914 18BR/WT SENSOR GROUND 48 K916 18BR/OR SENSOR GROUND 49 - 50 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL 51 K613 16GY/BR INJECTOR HIGH SIDE DRIVER NO. 3 52 K612 16YL/BR INJECTOR HIGH SIDE DRIVER NO. 2 53 K611 16OR/BR INJECTOR HIGH SIDE DRIVER NO. 1 54 K14 16BR/TN INJECTOR CONTROL NO. 4 55 K38 16GY INJECTOR CONTROL NO. 5 56 K13 16TN INJECTOR CONTROL NO. 3 57 K11 16BR/YL INJECTOR CONTROL NO. 1 58 K658 16LG/BR INJECTOR HIGH SIDE DRIVER NO. 6 59 K638 16LB/BR INJECTOR HIGH SIDE DRIVER NO. 5 60 K614 16WT/BR INJECTOR HIGH SIDE DRIVER NO. 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 453 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 454 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 455 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Circuit Description 1-2-3 K23 18BR/WT APPS NO. 1 SIGNAL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 456 5 T515 18YL/DB TRANSMISSION CONTROL 6 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 7 K31 18BR FUEL PUMP CONTROL 8-9 T41 18YL/DB TRS T41 SIGNAL (P/N) 10 - 11 - 12 - 13 T6 18DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 14 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 15 T9 18DG/TN 3-4 SOLENOID CONTROL 16 - 17 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 18 - 19 - 20 A209 16RD FUSED B(+) 21 Z902 16BK GROUND 22 - 23 F856 18YL/PK 5 VOLT SUPPLY 24 K900 18DB/DG SENSOR GROUND 25 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 26 - 27 K312 18OR TTVA POSITION SENSOR SIGNAL 28 - 29 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL 30 A209 16RD FUSED B(+) 31 - 32 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 K854 18VT/BR 5 VOLT SUPPLY 34 - 35 K29 18WT/BR APPS NO. 2 SIGNAL 36 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 37 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 38 - 39 - 40 A209 16RD FUSED B(+) 41 C13 18LB/OR A/C CLUTCH CONTROL 42 - 43 K160 18BR/OR PWM FAN COIL SIGNAL 44 T14 18DG/BR OUTPUT SPEED SIGNAL 45 T13 18DG/VT SPEED SENSOR GROUND 46 V37 18VT S/C SWITCH NO. 1 SIGNAL 47 K25 18DB/VT BATT TEMP SIGNAL 48 K400 18BR/VT APPS NO. 2 RETURN 49 Z902 16BK GROUND 50 Z902 16BK GROUND Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 457 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 458 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 459 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 D65 18WT/LG CAN C BUS (+) 2 K31 18BR FUEL PUMP CONTROL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 460 5 G905 18BR/OR EXHAUST BRAKE SWITCH SIGNAL 6 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 7 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 8 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 9 K186 18BR/OR EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 10 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 11 - 12 - 13 - 14 - 15 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 16 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 17 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 18 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 19 - 20 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 21 D64 18WT/LB CAN C BUS (-) 22 K400 18BR/VT APPS NO. 2 RETURN 23 - 24 K29 18WT/BR APPS NO. 2 SIGNAL 25 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 26 K854 18VT/BR 5 VOLT SUPPLY 27 K852 18BR/LB 5 VOLT SUPPLY 28 K167 18BR/DG APPS NO. 1 RETURN 29 K900 18DB/DG SENSOR GROUND 30 K25 18DB/VT BATT TEMP SIGNAL 31 D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK 32 - 33 V937 18VT/BR S/C SWITCH RETURN 34 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 35 K23 18BR/WT APPS NO. 1 SIGNAL 36 - - 37 K128 18DG/LG REMOTE THROTTLE SIGNAL 38 - 39 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 40 V37 18VT S/C SWITCH NO. 1 SIGNAL 41 - 42 - 43 K348 18BR SMART POWER RELAY RETURN 44 C13 18LB A/C CLUTCH CONTROL 45 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 46 - 47 Z902 16BK GROUND 48 Z902 16BK GROUND 49 A209 16RD FUSED B(+) 50 A209 16RD FUSED B(+) 51 D132 18WT DIAGNOSTIC PORT LOW DATA LINK 52 - 53 - 54 G904 18VT/DG EXHAUST BRAKE LAMP SIGNAL 55 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 56 V38 18VT/OR S/C SWITCH NO. 2 SIGNAL 57 Z902 16BK GROUND 58 - 59 - 60 A209 16RD FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 461 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 462 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 463 Component ID 198 Component ID: 198 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 464 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 - 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 465 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 466 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 467 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 468 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 469 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 470 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 471 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 472 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 473 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 474 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 475 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 476 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 477 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 478 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 479 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 480 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 481 Component ID 211 Component ID: 211 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 482 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 - 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 483 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 484 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 485 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 486 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 487 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 488 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 489 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 490 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 491 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 492 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 494 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 495 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 496 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 497 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 498 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 499 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel Engine Control Module: Description and Operation Engine Control Module (ECM) - Diesel Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 502 The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 503 - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 504 Engine Control Module: Description and Operation Powertrain Control Module - Description Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors Modes Of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 505 IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD or O2S heater relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 506 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 507 - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Ignition Circuit Sense IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). Power Grounds POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 508 Sensor Return SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 509 Engine Control Module: Description and Operation Powertrain Control Module - Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for a scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 510 - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for diagnostic scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission convertor clutch circuit. Driven through J1850 circuits. 5 Volt Supplies 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel Engine Control Module: Testing and Inspection Engine Control Module (ECM) - Diesel ECM/PCM PROGRAMMING MODULE REPROGRAMING Replacement ECM's will require programming utilizing the StarSCAN(R) or equivalent. The ECM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic ECM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN and StarMOBILE or equivalent Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. NOTE: For the Cummins Diesel, if the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. 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. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 513 6. Replace the ECM with the appropriate Generic ECM. 7. Program the ECM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the ECM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "ECM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 10. 10. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a ECM and/or TCM. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 514 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. 5. Replace the ECM with the appropriate Generic ECM. . 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select "More Options". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 515 c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the ECM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "ECM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle is equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the ECM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 516 Engine Control Module: Testing and Inspection PCM/ECM Programming ECM/PCM PROGRAMMING MODULE REPROGRAMING Replacement ECM's will require programming utilizing the StarSCAN(R) or equivalent. The ECM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic ECM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN and StarMOBILE or equivalent Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. NOTE: For the Cummins Diesel, if the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. 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. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 517 6. Replace the ECM with the appropriate Generic ECM. 7. Program the ECM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the ECM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "ECM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 10. 10. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a ECM and/or TCM. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 518 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. 5. Replace the ECM with the appropriate Generic ECM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select "More Options". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 519 c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the ECM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "ECM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle is equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the ECM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 520 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED , ECM REPLACED , WCM REPLACED , or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 521 SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 522 Engine Control Module: Testing and Inspection Powertrain Control Module PCM/ECM REPROGRAMMING - GAS MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN(R) or equivalent and StarMOBILE Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is this a GPEC Module? a. Yes >> go to STEP 9. b. No >> go to STEP 12. 9. Do not start the engine prior to completing the following steps (a. and b.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 523 a. Turn the ignition switch to the OFF position for no less than 15 seconds. b. Turn the ignition to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. 10. Is this vehicle equipped with a CVT? a. Yes >> go to STEP 11. b. No >> go to STEP 17. 11. The TCM must be reprogrammed as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. NOTE: If the part number recorded in step "11e" is the same as the new p/n shown on the "Flash File List" screen no further action is required. Cancel the TCM reprogram procedure. Continue to step STEP 17. g. Highlight the appropriate calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". m. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. n. Continue to step STEP 15 12. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 13. b. No >> go to STEP 14. 13. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 15. 14. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 15. Is the vehicle equipped ETC? a. Yes >> go to STEP 17. b. No >> go to STEP 16. 16. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 17. Type the necessary information on the Authorized Modification Label p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 524 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R) or equivalent, refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under Training Aids and also under Download Center > Frequently Asked Questions for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 525 d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel Engine Control Module: Service and Repair Engine Control Module (ECM) - Diesel 5.9L Diesel 5.9L DIESEL CUMMINS FUEL SYSTEM COMPONENTS The Engine Control Module (ECM) (16) is bolted to a support bracket near the fuel filter. The support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. 3. Remove the 50-way and 60-way connector bolts at the ECM. Note: The connector bolt is a female allen head. As bolt is being removed, very carefully remove connectors from the ECM. 4. Remove five ECM mounting bolts and remove ECM from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 528 6.7L Diesel 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. 5.9L Diesel 5.9L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 529 CUMMINS FUEL SYSTEM COMPONENTS Do not apply paint to ECM or a poor ground will result. 1. Position the ECM (16) to the ECM support bracket and install the five mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pin connectors in ECM, 50-way and 60-way connectors for corrosion or damage. Repair as necessary. 3. Clean pins in the 50-way and 60-way electrical connectors with a electrical contact cleaner. 4. Install the 50-way and 60-way connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Reconnect both negative battery cables. 6. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. 6.7L Diesel 6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 530 Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM.FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 531 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 532 Engine Control Module: Service and Repair Powertrain Control Module - Removal REMOVAL CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (4) and remove PCM from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 533 Engine Control Module: Service and Repair Powertrain Control Module - Installation INSTALLATION CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The scan tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 537 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 538 Main Relay (Computer/Fuel System): Diagrams Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 539 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 540 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 541 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 551 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 552 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 553 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 554 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 555 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 556 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 557 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 558 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 559 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 560 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 561 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 562 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 563 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 564 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 565 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 566 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 567 Fuel Pump Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 568 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 Intake Air Heater Relay: Locations Component ID 242 Component ID: 242 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 573 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 574 Intake Air Heater Relay: Locations Component ID 243 Component ID: 243 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 575 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 Intake Air Heater Relay: Diagrams Component ID 242 Component ID: 242 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 578 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 579 Intake Air Heater Relay: Diagrams Component ID 243 Component ID: 243 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 580 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Page 581 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 584 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 588 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 589 Main Relay (Computer/Fuel System): Diagrams Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 590 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 591 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 592 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Component ID: 210 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Circuit Description 1-2-3 D55 20WT/OR CAN B BUS (+) 4 D54 20WT CAN B BUS (-) 5-6 G104 20VT/GY PASSENGER AIRBAG INDICATOR DRIVER 7 R104 20LB/LG PASSENGER AIRBAG MUX SWITCH RETURN 8 R106 20LG/LB PASSENGER AIRBAG MUX SWITCH SENSE 9 R81 20LB/WT LEFT FRONT IMPACT SENSOR GROUND 10 R79 20LB/VT LEFT FRONT IMPACT SENSOR SIGNAL 11 R82 20WT/LB RIGHT FRONT IMPACT SENSOR GROUND 12 R80 20VT/LB RIGHT FRONT IMPACT SENSOR SIGNAL 13 - 14 - 15 - 16 - 17 R43 20LG/BR DRIVER SQUIB 1 LINE 1 18 R45 20LG/OR DRIVER SQUIB 1 LINE 2 19 R44 20LB/OR PASSENGER SQUIB 1 LINE 2 20 R42 20LB/BR PASSENGER SQUIB 1 LINE 1 21 R61 20LG/VT DRIVER SQUIB 2 LINE 1 22 R63 20LG/WT DRIVER SQUIB 2 LINE 2 23 R64 20LB/WT PASSENGER SQUIB 2 LINE 1 24 R62 20LB/VT PASSENGER SQUIB 2 LINE 2 Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 597 Component Location - 63 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 598 Component Location - 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 599 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Circuit Description 1 R2 20WT/LB RIGHT CURTAIN SQUIB 1 LINE 2 2 R4 20OR/LB RIGHT CURTAIN SQUIB 1 LINE 1 3 R3 20LB/OR LEFT CURTAIN SQUIB 1 LINE 1 4 R1 20LB/WT LEFT CURTAIN SQUIB 1 LINE 2 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 600 6-7-8-9 R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2 10 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1 11 R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 12 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 13 R1 20LB/WT LEFT CURTAIN SQUIB 1 LINE 2 14 R3 20LB/OR LEFT CURTAIN SQUIB 1 LINE 1 15 R4 20OR/LB RIGHT CURTAIN SQUIB 1 LINE 1 16 R2 20WT/LB RIGHT CURTAIN SQUIB 1 LINE 2 17 F201 20PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START) 18 F100 20PK/VT FUSED IGNITION SWITCH OUTPUT (RUN) 19 - 20 Z104 18BK/LG GROUND 21 - 22 - 23 - 24 - 25 R261 20LB/TN DRIVER SEAT POSITION SENSOR DATA 26 R263 20LB/GY DRIVER SEAT POSITION SENSOR VOLTAGE 27 R14 20TN/LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL 28 R16 20BR/LG RIGHT SIDE IMPACT SENSOR 1 GROUND 29 R15 20LG/BR LEFT SIDE IMPACT SENSOR 1 GROUND 30 R13 20LG/TN LEFT SIDE IMPACT SENSOR 1 SIGNAL 31 - 32 - Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 601 Component Location - 63 Component Location - 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 602 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 603 Air Bag Control Module: Diagrams Component ID: 210 Component : MODULE-OCCUPANT RESTRAINT CONTROLLER Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 Color : YELLOW # of pins : 24 Pin Circuit Description 1-2-3 D55 20WT/OR CAN B BUS (+) 4 D54 20WT CAN B BUS (-) 5-6 G104 20VT/GY PASSENGER AIRBAG INDICATOR DRIVER 7 R104 20LB/LG PASSENGER AIRBAG MUX SWITCH RETURN 8 R106 20LG/LB PASSENGER AIRBAG MUX SWITCH SENSE 9 R81 20LB/WT LEFT FRONT IMPACT SENSOR GROUND 10 R79 20LB/VT LEFT FRONT IMPACT SENSOR SIGNAL 11 R82 20WT/LB RIGHT FRONT IMPACT SENSOR GROUND 12 R80 20VT/LB RIGHT FRONT IMPACT SENSOR SIGNAL 13 - 14 - 15 - 16 - 17 R43 20LG/BR DRIVER SQUIB 1 LINE 1 18 R45 20LG/OR DRIVER SQUIB 1 LINE 2 19 R44 20LB/OR PASSENGER SQUIB 1 LINE 2 20 R42 20LB/BR PASSENGER SQUIB 1 LINE 1 21 R61 20LG/VT DRIVER SQUIB 2 LINE 1 22 R63 20LG/WT DRIVER SQUIB 2 LINE 2 23 R64 20LB/WT PASSENGER SQUIB 2 LINE 1 24 R62 20LB/VT PASSENGER SQUIB 2 LINE 2 Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 604 Component Location - 63 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 605 Component Location - 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 606 Connector: Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C2 Color : YELLOW # of pins : 32 Pin Circuit Description 1 R2 20WT/LB RIGHT CURTAIN SQUIB 1 LINE 2 2 R4 20OR/LB RIGHT CURTAIN SQUIB 1 LINE 1 3 R3 20LB/OR LEFT CURTAIN SQUIB 1 LINE 1 4 R1 20LB/WT LEFT CURTAIN SQUIB 1 LINE 2 5-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 607 6-7-8-9 R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2 10 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1 11 R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 12 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 13 R1 20LB/WT LEFT CURTAIN SQUIB 1 LINE 2 14 R3 20LB/OR LEFT CURTAIN SQUIB 1 LINE 1 15 R4 20OR/LB RIGHT CURTAIN SQUIB 1 LINE 1 16 R2 20WT/LB RIGHT CURTAIN SQUIB 1 LINE 2 17 F201 20PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START) 18 F100 20PK/VT FUSED IGNITION SWITCH OUTPUT (RUN) 19 - 20 Z104 18BK/LG GROUND 21 - 22 - 23 - 24 - 25 R261 20LB/TN DRIVER SEAT POSITION SENSOR DATA 26 R263 20LB/GY DRIVER SEAT POSITION SENSOR VOLTAGE 27 R14 20TN/LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL 28 R16 20BR/LG RIGHT SIDE IMPACT SENSOR 1 GROUND 29 R15 20LG/BR LEFT SIDE IMPACT SENSOR 1 GROUND 30 R13 20LG/TN LEFT SIDE IMPACT SENSOR 1 SIGNAL 31 - 32 - Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 608 Component Location - 63 Component Location - 51 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 609 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Description Seat Occupant Classification Module - Air Bag: Description and Operation Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is located in the passenger compartment of the vehicle, where it is secured by three nuts to three studs on a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel under the center front seat section or the center floor console, as the vehicle is equipped. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three corners. The mounting flange to the right of the connector receptacles (4) has an integral locating pin on its lower surface. Both right side flanges have round mounting holes, while the flange on the left side has a slotted mounting hole. A molded plastic electrical connector (4) with 2 receptacles, one containing 24 terminal pins and the other containing 32 terminal pins, exits the forward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors, one each from the instrument panel and the body wire harnesses. A molded plastic protective cover is installed over the ORC to provide additional moisture contamination protection to the unit. Integral latch features on each side of the cover engage a slot (5) on each side of the base of the ORC housing to secure the cover to the ORC. This protective cover must be reinstalled following any service requiring its removal. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for light and heavy-duty vehicles, and for vehicles with or without the optional side curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Description > Page 614 Seat Occupant Classification Module - Air Bag: Description and Operation Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the Supplemental Restraint System (SRS) logic circuits and controls all of the SRS components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. See: Restraint Systems/Air Bag Systems/Malfunction Lamp / Indicator/Description and Operation/Operation . The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. In standard cab vehicles (except light-duty DR 1500), the ORC also monitors a resistor multiplexed input from the passenger airbag on/off switch. If the passenger airbag on/off switch is set to the OFF position, the ORC turns ON the passenger airbag on/off indicator and will internally disable the passenger airbag and, on light-duty DR 1500 only, the seat belt tensioner from being deployed. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused ignition switch output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw to the instrument panel structural support. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left ends of the lower radiator crossmember near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provide verification of the direction and severity of an impact. On vehicles equipped with optional side curtain airbags the ORC also monitors inputs from two additional remote impact sensors located within both the left and right B-pillars to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a SRS deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels and, if the vehicle is so equipped, the front seat belt tensioners or either side curtain airbag unit. On standard cab vehicles except light-duty DR 1500, the passenger front airbag will be deployed by the ORC only if enabled by the passenger airbag on/off switch at the time of the impact. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Occupant Restraint Controller (ORC) Module - Removal Seat Occupant Classification Module - Air Bag: Service and Repair Occupant Restraint Controller (ORC) Module - Removal MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the protective cover from the Occupant Restraint Controller (ORC) (1). See: Occupant Restraint Controller (ORC) Module Cover Removal . 3. Unlatch and disconnect the two wire harness connectors (3) for the ORC from the ORC connector receptacles (2 and 4) located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 4. Remove the three nuts (2) that secure the ORC (1) to the studs on the ORC mounting bracket (3) on the floor panel transmission tunnel. 5. Remove the ORC from the floor panel transmission tunnel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Occupant Restraint Controller (ORC) Module - Removal > Page 617 Seat Occupant Classification Module - Air Bag: Service and Repair Occupant Restraint Controller (ORC) Module Cover - Removal COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. NOTE: The front seat assembly must be unfastened from the floor panel, but need not be removed from the vehicle for access to the Occupant Restraint Controller (ORC) cover for service. 2. Remove the front seat from the vehicle. See: Body and Frame/Seats/Service and Repair/Seat Removal . 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry the latch feature on either side of the ORC cover (1) away from the base of the ORC (2) far enough to disengage the cover from the module. 4. Remove the ORC cover from over the ORC. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Occupant Restraint Controller (ORC) Module - Removal > Page 618 Seat Occupant Classification Module - Air Bag: Service and Repair Occupant Restraint Controller (ORC) Module - Installation MODULE WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Position the Occupant Restraint Controller (ORC) (1) over the three studs of the ORC mounting bracket (3) on the floor panel transmission tunnel, then engage the locating pin on the bottom of the right ORC mounting flange into the locating hole in the bracket. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle. 2. Install and tighten the three nuts (2) that secure the ORC to the bracket on the floor panel transmission tunnel. Tighten the nuts to 10 Nm (7 ft. lbs.). 3. Reconnect the two wire harness connectors (3) for the ORC (1) to the ORC connector receptacles (2 and 4) located on the forward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 4. Reinstall the ORC cover onto the ORC. See: Occupant Restraint Controller (ORC) Module Cover - Installation . 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Service and Repair > Occupant Restraint Controller (ORC) Module - Removal > Page 619 Seat Occupant Classification Module - Air Bag: Service and Repair Occupant Restraint Controller (ORC) Module Cover - Installation COVER WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the ORC cover (1) over the Occupant Restraint Controller (ORC) (2). 2. Align the latch feature on each side of the ORC cover with the notch in each side at the base of the ORC housing. 3. Using hand pressure, press firmly and evenly downward on the ORC cover until each latch feature is fully engaged with the ORC housing. 4. Reinstall the front seat into the vehicle. See: Body and Frame/Seats/Service and Repair/Seat - Installation . 5. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Component ID: 214 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Circuit Description 1 Z909 20BK GROUND 2 X20 20GY/WT RADIO CONTROL MUX 3 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 4 V37 20VT S/C SWITCH NO. 1 SIGNAL 5 V937 20VT/BR S/C SWITCH RETURN 6 X3 20DG/VT HORN SWITCH SENSE Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 625 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 626 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 627 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Circuit Description 1 G902 22WT/BR SWITCH MUX RETURN Pin Circuit Description 1 G902 22WT/BR SWITCH MUX RETURN Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 628 2 X20 22GY/WT RADIO CONTROL MUX 2 X20 22GY/WT RADIO CONTROL MUX Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 629 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 630 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Circuit Description 1 X3 20DG/VT HORN SWITCH SENSE 2 V937 22DB/DG S/C SWITCH RETURN 2 K900 22DB/DG SENSOR GROUND 3 V37 22VT S/C SWITCH NO. 1 SIGNAL 4 V38 22VT/OR S/C SWITCH NO. 2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 631 Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 632 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 633 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Circuit Description 1 R61 20LG/VT DRIVER SQUIB 2 LINE 1 2 R63 20LG/WT DRIVER SQUIB 2 LINE 2 3 R43 20LG/BR DRIVER SQUIB 1 LINE 1 4 R45 20LG/OR DRIVER SQUIB 1 LINE 2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 634 Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 635 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 636 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 637 Steering Mounted Controls Communication Module: Diagrams Component ID: 214 Component : MODULE-STEERING CONTROL Connector: Name : MODULE-STEERING CONTROL C1 Color : WHITE # of pins : 6 Pin Circuit Description 1 Z909 20BK GROUND 2 X20 20GY/WT RADIO CONTROL MUX 3 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 4 V37 20VT S/C SWITCH NO. 1 SIGNAL 5 V937 20VT/BR S/C SWITCH RETURN 6 X3 20DG/VT HORN SWITCH SENSE Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 638 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 639 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 640 Connector: Name : MODULE-STEERING CONTROL C2 Color : BLACK # of pins : 2 Qualifier : (PREMIUM) Pin Circuit Description 1 G902 22WT/BR SWITCH MUX RETURN Pin Circuit Description 1 G902 22WT/BR SWITCH MUX RETURN Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 641 2 X20 22GY/WT RADIO CONTROL MUX 2 X20 22GY/WT RADIO CONTROL MUX Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 642 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 643 Connector: Name : MODULE-STEERING CONTROL C3 Color : # of pins : 4 Pin Circuit Description 1 X3 20DG/VT HORN SWITCH SENSE 2 V937 22DB/DG S/C SWITCH RETURN 2 K900 22DB/DG SENSOR GROUND 3 V37 22VT S/C SWITCH NO. 1 SIGNAL 4 V38 22VT/OR S/C SWITCH NO. 2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 644 Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 645 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 646 Connector: Name : MODULE-STEERING CONTROL C4 Color : YELLOW # of pins : 4 Pin Circuit Description 1 R61 20LG/VT DRIVER SQUIB 2 LINE 1 2 R63 20LG/WT DRIVER SQUIB 2 LINE 2 3 R43 20LG/BR DRIVER SQUIB 1 LINE 1 4 R45 20LG/OR DRIVER SQUIB 1 LINE 2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 647 Component Location - 47 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 648 Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 649 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID 521 Component ID: 521 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-- Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 655 Component ID 523 Component ID: 523 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 656 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 657 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Front Component ID 522 Component ID: 522 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-- Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 658 Component ID 524 Component ID: 524 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 659 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID 521 Component ID: 521 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-- Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 662 Component ID 523 Component ID: 523 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 663 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 664 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Front Component ID 522 Component ID: 522 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-- Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 665 Component ID 524 Component ID: 524 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 666 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder (2), also known as a trigger module, is located in the front wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the front tire pressure sensors on the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 669 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION The Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in the front wheel wells on the vehicle to provide it with the location of the front tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 20 minutes or longer). If the TPMS fails to localize, the TPM indicator lamp will flash on/off for 75 seconds, and remain on solid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > TPM Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair TPM Transponder - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel well housing cover. 3. Remove the mounting screw (1) for the transponder (2). 4. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > TPM Transponder - Removal > Page 672 Tire Pressure Monitor Receiver / Transponder: Service and Repair TPM Transponder - Installation INSTALLATION 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3). 2. Install the mounting screw (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover. 4. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 683 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 684 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 690 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 691 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 Control Module: Locations Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 694 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 695 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 696 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 697 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 698 Control Module: Locations Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 699 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 700 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 701 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 702 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 Control Module: Diagrams Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 705 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 706 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 707 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 708 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 709 Control Module: Diagrams Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 710 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 711 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 712 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 713 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 716 On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 717 Control Module: Description and Operation Transmission Control Module - Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Powertrain Management/Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 718 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 719 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 720 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 721 Some examples of TCM.indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations The Transmission Control Relay is not serviceable if equipped Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 727 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 728 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 729 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 730 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 731 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 732 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 733 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 734 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 735 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 736 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 737 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 738 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 739 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 740 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 741 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 742 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 743 Transmission Control System Relay: Connector Views Component ID: 246 Component : RELAY-TRANSMISSION Connector: Name : RELAY-TRANSMISSION Color : # of pins : 4 Pin Circuit Description 1 A916 16RD FUSED B(+) 2 T16 16YL TRANSMISSION CONTROL OUTPUT 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 Z420 18BK GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 Control Module: Locations Component ID 197 Component ID: 197 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 751 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 752 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 753 Control Module: Locations Component ID 206 Component ID: 206 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 754 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 755 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 Control Module: Diagrams Component ID 197 Component ID: 197 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 758 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 759 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 760 Control Module: Diagrams Component ID 206 Component ID: 206 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 761 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 762 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location and additional information. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 765 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ±0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ±1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ±1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ±100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 766 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ±100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ±100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ±50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ±100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ±50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ±100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ±50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ±100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ±50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 767 TIPM waits for 2.0 seconds ±50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ±100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TIPM will wait for 2.0 seconds ±50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 768 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ±100 msec calibrated window of time. After 5 minutes ±100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 773 Heated Glass Element Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 777 Rear Defogger Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Dodge Ram 2006-2008, 1500-5500 all, do not use a wiper relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 782 Wiper Relay: Description and Operation Dodge Ram 2006-2009, does not use a wiper relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component ID 475 Hood Sensor/Switch (For Alarm): Locations Component ID 475 Component ID: 475 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 G70 20VT/LB HOOD AJAR SWITCH SENSE 2 G930 20VT/TN AAT RETURN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component ID 475 > Page 789 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component ID 475 > Page 790 Hood Sensor/Switch (For Alarm): Locations Component ID 492 Component ID: 492 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 G70 20VT/LB HOOD AJAR SWITCH SENSE 2 G930 20VT/TN AAT RETURN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component ID 475 > Page 791 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams > Component ID 475 Hood Sensor/Switch (For Alarm): Diagrams Component ID 475 Component ID: 475 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 G70 20VT/LB HOOD AJAR SWITCH SENSE 2 G930 20VT/TN AAT RETURN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams > Component ID 475 > Page 794 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams > Component ID 475 > Page 795 Hood Sensor/Switch (For Alarm): Diagrams Component ID 492 Component ID: 492 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 G70 20VT/LB HOOD AJAR SWITCH SENSE 2 G930 20VT/TN AAT RETURN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams > Component ID 475 > Page 796 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 799 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Hood Ajar Switch Bracket Hood Sensor/Switch (For Alarm): Service and Repair Hood Ajar Switch Bracket Removal BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). See: Hood Ajar Switch Removal . 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Installation BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. See: Hood Ajar Switch - Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Hood Ajar Switch Bracket > Page 802 Hood Sensor/Switch (For Alarm): Service and Repair Hood Ajar Switch Striker Removal STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Installation STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Hood Ajar Switch Bracket > Page 803 Hood Sensor/Switch (For Alarm): Service and Repair Hood Ajar Switch - Removal SWITCH 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Hood Ajar Switch Bracket > Page 804 Hood Sensor/Switch (For Alarm): Service and Repair Hood Ajar Switch - Installation SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Component ID: 480 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Circuit Description 1 P206 18LG/LB ADJUSTABLE PEDALS MOTOR REARWARD 2 A72 18RD/OR ADJUSTABLE PEDALS OUTPUT 3-4 Z146 18BK GROUND 5 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 6 P205 18LG/WT ADJUSTABLE PEDALS MOTOR FORWARD Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 808 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 809 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 810 Pedal Positioning Switch: Diagrams Component ID: 480 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Circuit Description 1 P206 18LG/LB ADJUSTABLE PEDALS MOTOR REARWARD 2 A72 18RD/OR ADJUSTABLE PEDALS OUTPUT 3-4 Z146 18BK GROUND 5 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 6 P205 18LG/WT ADJUSTABLE PEDALS MOTOR FORWARD Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 811 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 812 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel (4) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Driver Side Bezel/Removal . 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 815 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Driver Side Bezel/Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left Remote Switch: Locations Switch-Remote Radio-Left Component ID: 504 Component : SWITCH-REMOTE RADIO-LEFT Connector: Name : SWITCH-REMOTE RADIO-LEFT Color : BLACK # of pins : 2 Pin Circuit Description 1 X20 22GY/WT RADIO CONTROL MUX 2 G902 22WT/BR GROUND Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 820 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 821 Remote Switch: Locations Switch-Remote Radio-Right Component ID: 505 Component : SWITCH-REMOTE RADIO-RIGHT Connector: Name : SWITCH-REMOTE RADIO-RIGHT Color : BLACK # of pins : 2 Pin Circuit Description 1 X20 22GY/WT RADIO CONTROL MUX 2 G902 22WT/BR GROUND Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 822 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left Remote Switch: Diagrams Switch-Remote Radio-Left Component ID: 504 Component : SWITCH-REMOTE RADIO-LEFT Connector: Name : SWITCH-REMOTE RADIO-LEFT Color : BLACK # of pins : 2 Pin Circuit Description 1 X20 22GY/WT RADIO CONTROL MUX 2 G902 22WT/BR GROUND Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 825 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 826 Remote Switch: Diagrams Switch-Remote Radio-Right Component ID: 505 Component : SWITCH-REMOTE RADIO-RIGHT Connector: Name : SWITCH-REMOTE RADIO-RIGHT Color : BLACK # of pins : 2 Pin Circuit Description 1 X20 22GY/WT RADIO CONTROL MUX 2 G902 22WT/BR GROUND Component Location - 43 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 827 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description Remote Switch: Description and Operation Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description > Page 830 Remote Switch: Description and Operation Operation OPERATION The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Totally Integrated Power Module (TIPM) through the clockspring. The TIPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the TIPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the TIPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 831 Remote Switch: Testing and Inspection REMOTE SWITCHES Any diagnosis of the Audio system should begin with the use of scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For a complete wiring diagram Refer to Diagrams/Electrical. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel See: Service and Repair/Removal . 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to STEP 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to STEP 5. If not OK, repair the open or shorted radio control mux circuit to the Totally Integrated Power Module (TIPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the TIPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to STEP 6. If not OK, repair the shorted remote radio switch ground circuit to the TIPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the TIPM. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the TIPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal Remote Switch: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Airbag Removal . 3. Remove the speed control switches (2) See: Sensors and Switches - Cruise Control/Cruise Control Switch/Service and Repair/Removal . 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal > Page 834 Remote Switch: Service and Repair Installation INSTALLATION WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2) See: Sensors and Switches - Cruise Control/Cruise Control Switch/Service and Repair/Installation . 4. Install the driver airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Airbag Installation . 5. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component ID 475 Hood Sensor/Switch (For Alarm): Locations Component ID 475 Component ID: 475 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 G70 20VT/LB HOOD AJAR SWITCH SENSE 2 G930 20VT/TN AAT RETURN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component ID 475 > Page 841 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component ID 475 > Page 842 Hood Sensor/Switch (For Alarm): Locations Component ID 492 Component ID: 492 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 G70 20VT/LB HOOD AJAR SWITCH SENSE 2 G930 20VT/TN AAT RETURN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component ID 475 > Page 843 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams > Component ID 475 Hood Sensor/Switch (For Alarm): Diagrams Component ID 475 Component ID: 475 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 G70 20VT/LB HOOD AJAR SWITCH SENSE 2 G930 20VT/TN AAT RETURN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams > Component ID 475 > Page 846 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams > Component ID 475 > Page 847 Hood Sensor/Switch (For Alarm): Diagrams Component ID 492 Component ID: 492 Component : SWITCH-HOOD AJAR Connector: Name : SWITCH-HOOD AJAR Color : # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 G70 20VT/LB HOOD AJAR SWITCH SENSE 2 G930 20VT/TN AAT RETURN Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams > Component ID 475 > Page 848 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description Hood Sensor/Switch (For Alarm): Description and Operation Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in two different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic vehicles equipped with an optional remote starter system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting bracket is secured with screws to the inboard side of the right front fender load beam within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 851 Hood Sensor/Switch (For Alarm): Description and Operation Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Totally Integrated Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic vehicles only - white retainer ring) the switch has a 1 kilohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the TIPM and the hood ajar switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export vehicle theft or domestic remote starter systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Hood Ajar Switch Bracket Hood Sensor/Switch (For Alarm): Service and Repair Hood Ajar Switch Bracket Removal BRACKET 1. Remove the hood ajar switch (2) from the mounting bracket (3). See: Hood Ajar Switch Removal . 2. Remove the two screws (4) that secure the hood ajar switch bracket to the two rivet nuts (1) in the right front load beam (6). 3. Remove the hood ajar switch mounting bracket from the inboard side of the right front load beam. Installation BRACKET 1. Check to be certain that the two rivet nuts (1) on the inboard side of the right front load beam (6) are in good condition and properly secured. 2. Position the hood ajar switch mounting bracket (3) onto the right front load beam. 3. Install and tighten the two screws (4) that secure the mounting bracket to the load beam. Beginning with the rearward screw, tighten both screws to 8 Nm (71 in. lbs.). 4. Reinstall the hood ajar switch (2) into the mounting bracket. See: Hood Ajar Switch - Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Hood Ajar Switch Bracket > Page 854 Hood Sensor/Switch (For Alarm): Service and Repair Hood Ajar Switch Striker Removal STRIKER NOTE: The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using a trim stick or another suitable wide flat-bladed tool, pry the rearward end of the hood ajar switch striker (2) away from the inner hood panel reinforcement (1) far enough to disengage the integral retainers from their mounting holes. 3. Remove the striker from the inner hood panel reinforcement and discard. Installation STRIKER NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) to the mounting holes in the inner hood panel reinforcement (1) over the hood ajar switch (3). 2. Using hand pressure, press the hood ajar switch striker upward into the mounting holes in the inner hood panel reinforcement until both integral retainers are fully engaged. 3. Close and latch the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Hood Ajar Switch Bracket > Page 855 Hood Sensor/Switch (For Alarm): Service and Repair Hood Ajar Switch - Removal SWITCH 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. 3. From the top of the mounting bracket (3) on the right front load beam (6), squeeze the two hood ajar switch (2) latch tabs together and pull the switch upward. 4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and disconnect the jumper wire harness connector (5) from the switch connector receptacle. 5. Remove the hood ajar switch from the mounting bracket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Hood Ajar Switch Bracket > Page 856 Hood Sensor/Switch (For Alarm): Service and Repair Hood Ajar Switch - Installation SWITCH 1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the right front load beam (6). 2. Route the jumper wire harness connector (5) through the switch mounting bracket and reconnect it to the switch connector receptacle. 3. From the top of the mounting bracket, press the switch downward into the mounting hole until the integral switch latch tabs lock it into place. 4. Reconnect the battery negative cable. 5. Close and latch the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Component ID: 480 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Circuit Description 1 P206 18LG/LB ADJUSTABLE PEDALS MOTOR REARWARD 2 A72 18RD/OR ADJUSTABLE PEDALS OUTPUT 3-4 Z146 18BK GROUND 5 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 6 P205 18LG/WT ADJUSTABLE PEDALS MOTOR FORWARD Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 860 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 861 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 862 Pedal Positioning Switch: Diagrams Component ID: 480 Component : SWITCH-ADJUSTABLE PEDALS Connector: Name : SWITCH-ADJUSTABLE PEDALS Color : BLUE # of pins : 6 Qualifier : (EXCEPT BASE) Pin Circuit Description 1 P206 18LG/LB ADJUSTABLE PEDALS MOTOR REARWARD 2 A72 18RD/OR ADJUSTABLE PEDALS OUTPUT 3-4 Z146 18BK GROUND 5 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 6 P205 18LG/WT ADJUSTABLE PEDALS MOTOR FORWARD Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 863 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 864 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel (4) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Driver Side Bezel/Removal . 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 867 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Driver Side Bezel/Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger Power Door Lock Switch: Locations Switch-Door Lock-Passenger Component ID: 485 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Circuit Description 1 G160 20VT/LG PASSENGER DOOR LOCK SWITCH MUX 2 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 3-4-5 Z917 20BK GROUND 6-Component Location - 56 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 872 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 873 Power Door Lock Switch: Locations Switch-Window/Door Lock-Driver Component ID: 518 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Circuit Description 1 Q612 14OR/DB RIGHT REAR WINDOW DRIVER (DOWN) 2 Q412 14OR/LB RIGHT REAR WINDOW DRIVER (UP) 3 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP) 4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP) 5 Q11 14OR/LG LEFT FRONT WINDOW DRIVER (UP) 6 Q26 12OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN) 7 G161 20VT/DG DRIVER DOOR LOCK SWITCH MUX 8 Z939 12BK GROUND 9 F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 10 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN) 11 Z939 18BK GROUND 12 Q21 14OR/WT LEFT FRONT WINDOW DRIVER (DOWN) Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 874 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Circuit Description 1 P71 20TN/DG LEFT MIRROR UP DRIVER 2 P195 18LG/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 3 A940 18RD FUSED B(+) 4 P74 18TN/OR RIGHT MIRROR LEFT DRIVER 5 Z939 18BK GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Switch-Door Lock-Passenger > Page 875 6 P75 20TN/LG LEFT MIRROR LEFT DRIVER 7 P72 18TN/GY RIGHT MIRROR UP DRIVER 8 Q15 12OR/LB WINDOW LOCK OUT SWITCH OUTPUT Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger Power Door Lock Switch: Diagrams Switch-Door Lock-Passenger Component ID: 485 Component : SWITCH-DOOR LOCK-PASSENGER Connector: Name : SWITCH-DOOR LOCK-PASSENGER Color : NATURAL # of pins : 6 Pin Circuit Description 1 G160 20VT/LG PASSENGER DOOR LOCK SWITCH MUX 2 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 3-4-5 Z917 20BK GROUND 6-Component Location - 56 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 878 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 879 Power Door Lock Switch: Diagrams Switch-Window/Door Lock-Driver Component ID 479 Component ID: 479 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Circuit Description 1 Q612 14OR/DB RIGHT REAR WINDOW DRIVER (DOWN) 2 Q412 14OR/LB RIGHT REAR WINDOW DRIVER (UP) 3 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP) 4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP) 5 Q11 14OR/LG LEFT FRONT WINDOW DRIVER (UP) 6 Q26 12OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN) 7 G161 20VT/DG DRIVER DOOR LOCK SWITCH MUX 8 Z939 12BK GROUND 9 F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 10 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN) 11 Z939 18BK GROUND 12 Q21 14OR/WT LEFT FRONT WINDOW DRIVER (DOWN) Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 880 Pin Circuit Description 1 P71 20TN/DG LEFT MIRROR UP DRIVER 2 P195 18LG/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 3 A940 18RD FUSED B(+) 4 P74 18TN/OR RIGHT MIRROR LEFT DRIVER 5 Z939 18BK GROUND 6 P75 20TN/LG LEFT MIRROR LEFT DRIVER 7 P72 18TN/GY RIGHT MIRROR UP DRIVER 8 Q15 12OR/LB WINDOW LOCK OUT SWITCH OUTPUT Component ID 518 Component ID: 518 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Circuit Description 1 Q612 14OR/DB RIGHT REAR WINDOW DRIVER (DOWN) 2 Q412 14OR/LB RIGHT REAR WINDOW DRIVER (UP) 3 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP) 4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP) 5 Q11 14OR/LG LEFT FRONT WINDOW DRIVER (UP) 6 Q26 12OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 881 7 G161 20VT/DG DRIVER DOOR LOCK SWITCH MUX 8 Z939 12BK GROUND 9 F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 10 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN) 11 Z939 18BK GROUND 12 Q21 14OR/WT LEFT FRONT WINDOW DRIVER (DOWN) Component Location - 55 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 882 Pin Circuit Description 1 P71 20TN/DG LEFT MIRROR UP DRIVER 2 P195 18LG/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 3 A940 18RD FUSED B(+) 4 P74 18TN/OR RIGHT MIRROR LEFT DRIVER 5 Z939 18BK GROUND 6 P75 20TN/LG LEFT MIRROR LEFT DRIVER 7 P72 18TN/GY RIGHT MIRROR UP DRIVER 8 Q15 12OR/LB WINDOW LOCK OUT SWITCH OUTPUT Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Switch-Door Lock-Passenger > Page 883 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Description Power Door Lock Switch: Description and Operation Description DESCRIPTION A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. - Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Description > Page 886 Power Door Lock Switch: Description and Operation Operation OPERATION The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch Power Door Lock Switch: Testing and Inspection Power Lock Switch POWER LOCK SWITCH The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. See: Diagnosis and Testing If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 889 Power Door Lock Switch: Testing and Inspection Diagnosis and Testing WINDOW/LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures . If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Power Lock Switch > Page 890 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch Power Door Lock Switch: Service and Repair Power Lock Switch Removal REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. See: Window/Door Lock Switch/Removal 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal 3. Remove the switch from the trim panel bezel. Installation INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation . 3. Connect battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch > Page 893 Power Door Lock Switch: Service and Repair Window/Door Lock Switch Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal . 3. Remove the switch from the trim panel bezel. Installation INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation . 3. Connect battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver Power Seat Switch: Diagrams Switch-Seat-Driver Component ID 476 Component ID: 476 Component : SWITCH-SEAT-DRIVER Connector: Name : SWITCH-SEAT-DRIVER Color : # of pins : 12 Qualifier : (HD) A A210 12OR/RD FUSED B(+) B Z939 14BK GROUND C-E P11 12LG/YL DRIVER SEAT REAR UP DRIVER F-G Z939 14BK GROUND H A210 12OR/RD FUSED B(+) J P13 12LG/OR DRIVER SEAT REAR DOWN DRIVER K P17 12LG/DG DRIVER SEAT HORIZONTAL REARWARD DRIVER L P15 12LG/BR DRIVER SEAT HORIZONTAL FORWARD DRIVER M P19 12LG/LB DRIVER SEAT FRONT UP DRIVER N P21 12LG/TN DRIVER SEAT FRONT DOWN DRIVER Connector: Name : SWITCH-SEAT-DRIVER Color : GRAY # of pins : 8 Qualifier : (LD) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 898 Pin Circuit Description 1 P19 12LG/LB DRIVER SEAT FRONT UP DRIVER 2 Z939 14BK GROUND 3 P15 12LG/WT DRIVER SEAT HORIZONTAL FORWARD DRIVER 4 A210 12OR/RD FUSED B(+) 5 P11 12LG/YL DRIVER SEAT REAR UP DRIVER 6 P17 12LG/DG DRIVER SEAT HORIZONTAL REARWARD DRIVER 7 P13 12LG/OR DRIVER SEAT REAR DOWN DRIVER 8 P21 12LG/TN DRIVER SEAT FRONT DOWN DRIVER Component ID 507 Component ID: 507 Component : SWITCH-SEAT-DRIVER Connector: Name : SWITCH-SEAT-DRIVER Color : # of pins : 12 Qualifier : (HD) A A210 12OR/RD FUSED B(+) B Z939 14BK GROUND C-E P11 12LG/YL DRIVER SEAT REAR UP DRIVER F-G Z939 14BK GROUND H A210 12OR/RD FUSED B(+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 899 J P13 12LG/OR DRIVER SEAT REAR DOWN DRIVER K P17 12LG/DG DRIVER SEAT HORIZONTAL REARWARD DRIVER L P15 12LG/BR DRIVER SEAT HORIZONTAL FORWARD DRIVER M P19 12LG/LB DRIVER SEAT FRONT UP DRIVER N P21 12LG/TN DRIVER SEAT FRONT DOWN DRIVER Connector: Name : SWITCH-SEAT-DRIVER Color : GRAY # of pins : 8 Qualifier : (LD) Gender : MALE Pin Circuit Description 1 P19 12LG/LB DRIVER SEAT FRONT UP DRIVER 2 Z939 14BK GROUND 3 P15 12LG/WT DRIVER SEAT HORIZONTAL FORWARD DRIVER 4 A210 12OR/RD FUSED B(+) 5 P11 12LG/YL DRIVER SEAT REAR UP DRIVER 6 P17 12LG/DG DRIVER SEAT HORIZONTAL REARWARD DRIVER 7 P13 12LG/OR DRIVER SEAT REAR DOWN DRIVER 8 P21 12LG/TN DRIVER SEAT FRONT DOWN DRIVER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 900 Power Seat Switch: Diagrams Switch-Seat-Passenger Component ID 477 Component ID: 477 Component : SWITCH-SEAT-PASSENGER Connector: Name : SWITCH-SEAT-PASSENGER Color : # of pins : 12 A A210 12OR/RD FUSED B(+) B Z939 14BK GROUND C-E P12 12LG/YL PASSENGER SEAT REAR UP DRIVER F-G Z939 14BK GROUND H A210 12OR/RD FUSED B(+) J P10 12LG/TN PASSENGER SEAT REAR DOWN DRIVER K P16 12LG/BR PASSENGER SEAT HORIZONTAL REARWARD DRIVER L P14 12LG/OR PASSENGER SEAT HORIZONTAL FORWARD DRIVER M P20 12LG/LB PASSENGER SEAT FRONT UP DRIVER N P18 12LG/OR PASSENGER SEAT FRONT DOWN DRIVER Component ID 508 Component ID: 508 Component : SWITCH-SEAT-PASSENGER Connector: Name : SWITCH-SEAT-PASSENGER Color : # of pins : 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Switch-Seat-Driver > Page 901 A A210 12OR/RD FUSED B(+) B Z939 14BK GROUND C-E P12 12LG/YL PASSENGER SEAT REAR UP DRIVER F-G Z939 14BK GROUND H A210 12OR/RD FUSED B(+) J P10 12LG/TN PASSENGER SEAT REAR DOWN DRIVER K P16 12LG/BR PASSENGER SEAT HORIZONTAL REARWARD DRIVER L P14 12LG/OR PASSENGER SEAT HORIZONTAL FORWARD DRIVER M P20 12LG/LB PASSENGER SEAT FRONT UP DRIVER N P18 12LG/OR PASSENGER SEAT FRONT DOWN DRIVER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Description Power Seat Switch: Description and Operation Description DESCRIPTION The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Description > Page 904 Power Seat Switch: Description and Operation Operation OPERATION When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 905 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If OK, See: Body and Frame/Seats/Seat Track/Testing and Inspection . If not OK, replace the inoperative power seat switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal Power Seat Switch: Service and Repair Power Seat Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal > Page 908 Power Seat Switch: Service and Repair Power Seat Switch - Installation INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver Seat Heater Switch: Locations Switch-Heated Seat-Driver Component ID: 490 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Circuit Description 1 Z301 20TN/BK GROUND 2 P301 20LG/OR PANEL LAMPS DRIVER 3 P693 18LG/WT DRIVER SEAT HEATER SUPPLY 4 A930 16RD FUSED B(+) 5-6 A930 16RD FUSED B(+) Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 913 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 914 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 915 Seat Heater Switch: Locations Switch-Heated Seat-Passenger Component ID: 491 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Circuit Description 1 Z302 20LG/BK GROUND 2 P301 20LG/OR PANEL LAMPS DRIVER 3 P95 18LG/WT PASSENGER SEAT HEATER SUPPLY 4 A930 16RD FUSED B(+) 5-6 A930 16RD FUSED B(+) Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 916 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Switch-Heated Seat-Driver > Page 917 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver Seat Heater Switch: Diagrams Switch-Heated Seat-Driver Component ID: 490 Component : SWITCH-HEATED SEAT-DRIVER Connector: Name : SWITCH-HEATED SEAT-DRIVER Color : DK. GRAY # of pins : 6 Pin Circuit Description 1 Z301 20TN/BK GROUND 2 P301 20LG/OR PANEL LAMPS DRIVER 3 P693 18LG/WT DRIVER SEAT HEATER SUPPLY 4 A930 16RD FUSED B(+) 5-6 A930 16RD FUSED B(+) Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 920 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 921 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 922 Seat Heater Switch: Diagrams Switch-Heated Seat-Passenger Component ID: 491 Component : SWITCH-HEATED SEAT-PASSENGER Connector: Name : SWITCH-HEATED SEAT-PASSENGER Color : GREEN # of pins : 6 Pin Circuit Description 1 Z302 20LG/BK GROUND 2 P301 20LG/OR PANEL LAMPS DRIVER 3 P95 18LG/WT PASSENGER SEAT HEATER SUPPLY 4 A930 16RD FUSED B(+) 5-6 A930 16RD FUSED B(+) Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 923 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Switch-Heated Seat-Driver > Page 924 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description Seat Heater Switch: Description and Operation Description DESCRIPTION Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. See: Service and Repair/Heated Seat Switch Removal for the switch/module replacement procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Description > Page 927 Seat Heater Switch: Description and Operation Operation OPERATION A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Center Bezel - Removal . 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 930 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Center Bezel - Installation . 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof / Moonroof Switch: Locations Component ID: 512 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A Q4 20OR/YL SUNROOF VENT SWITCH SENSE B Q6 20OR/LG SUNROOF SWITCH SUPPLY C Q3 20OR/TN SUNROOF OPEN SWITCH SENSE D Q5 20OR/LB SUNROOF CLOSE SWITCH SENSE Component Location - 53 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 935 Sunroof / Moonroof Switch: Diagrams Component ID: 512 Component : SWITCH-SUNROOF Connector: Name : SWITCH-SUNROOF Color : BLACK # of pins : 4 A Q4 20OR/YL SUNROOF VENT SWITCH SENSE B Q6 20OR/LG SUNROOF SWITCH SUPPLY C Q3 20OR/TN SUNROOF OPEN SWITCH SENSE D Q5 20OR/LB SUNROOF CLOSE SWITCH SENSE Component Location - 53 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 936 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch Sunroof / Moonroof Switch: Description and Operation Sunroof Switch Description DESCRIPTION The power sunroof switch (3) is a combination push-button and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console/Removal . Operation OPERATION The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions. When one of the switch positions is pressed it sends battery current back to the motor/module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 939 Sunroof / Moonroof Switch: Testing and Inspection SWITCH - POWER SUNROOF For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console/Removal . 3. Disconnect the power sunroof switch wire harness connector. 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Component ID: 404 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Circuit Description 1 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE 2 Z420 20BK/OR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 944 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 945 Brake Fluid Level Sensor/Switch: Diagrams Component ID: 404 Component : SENSOR-BRAKE FLUID LEVEL Connector: Name : SENSOR-BRAKE FLUID LEVEL Color : BLACK # of pins : 2 Pin Circuit Description 1 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE 2 Z420 20BK/OR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 946 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Lateral Accelerometer: Locations Component ID: 408 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Circuit Description 1 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 2 D465 20WT/GY DYNAMICS SENSOR HIGH DATA LINK 3 D464 20WT/OR DYNAMICS SENSOR LOW DATA LINK 4-5-6 Z608 20BK/LG GROUND Component Location - 52 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 950 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 951 Lateral Accelerometer: Diagrams Component ID: 408 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Circuit Description 1 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 2 D465 20WT/GY DYNAMICS SENSOR HIGH DATA LINK 3 D464 20WT/OR DYNAMICS SENSOR LOW DATA LINK 4-5-6 Z608 20BK/LG GROUND Component Location - 52 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 952 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 953 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal Lateral Accelerometer: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder See: Body and Frame/Interior Moulding / Trim/Drink Holders/Service and Repair/Removal . 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Removal > Page 956 Lateral Accelerometer: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. See: Body and Frame/Interior Moulding / Trim/Drink Holders/Service and Repair/Installation . 5. Install the center bezel lower trim panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 497 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Circuit Description 1 B25 20DG/WT PARK BRAKE SWITCH SENSE Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 960 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 961 Parking Brake Warning Switch: Diagrams Component ID: 497 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Circuit Description 1 B25 20DG/WT PARK BRAKE SWITCH SENSE Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 962 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 965 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 966 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. Refer to appropriate testing. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 969 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations Steering Angle Sensor: Locations Component ID: 440 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Circuit Description 1 D65 20WT/LG CAN C BUS (+) 2 Z455 20BK/PK GROUND 3 D64 20WT/LB CAN C BUS (-) 4 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 973 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 974 Steering Angle Sensor: Diagrams Component ID: 440 Component : SENSOR-STEERING ANGLE Connector: Name : SENSOR-STEERING ANGLE Color : BLACK # of pins : 4 Pin Circuit Description 1 D65 20WT/LG CAN C BUS (+) 2 Z455 20BK/PK GROUND 3 D64 20WT/LB CAN C BUS (-) 4 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 975 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Traction Control Switch: Locations Component ID: 486 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Circuit Description 1 Z936 20BK/DG GROUND 2 E11 20OR/DB PANEL LAMPS DRIVER 3 B46 20DG/WT ESP ON/OFF SENSE 4 G94 20VT/DB SENSOR GROUND 5-6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 979 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 980 Traction Control Switch: Diagrams Component ID: 486 Component : SWITCH-ESP Connector: Name : SWITCH-ESP Color : # of pins : 6 Pin Circuit Description 1 Z936 20BK/DG GROUND 2 E11 20OR/DB PANEL LAMPS DRIVER 3 B46 20DG/WT ESP ON/OFF SENSE 4 G94 20VT/DB SENSOR GROUND 5-6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 981 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 982 Traction Control Switch: Description and Operation DESCRIPTION The ESP switch is located just below the heater and air conditioner controls in the center stack area of the instrument panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal Traction Control Switch: Service and Repair Removal REMOVAL 1. Remove the radio trim panel (1). 2. Disconnect the electrical connectors from the radio trim panel. 3. Remove the ESP switch (1) from the switch bank (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Removal > Page 985 Traction Control Switch: Service and Repair Installation INSTALLATION 1. Install the new switch (1) in the switch bank (2). 2. Reconnect the electrical connectors for the radio trim panel. 3. Install the radio trim panel (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Front Component ID: 448 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Circuit Description 1 B9 20DG/LG LEFT FRONT WHEEL SPEED SENSOR (+) Pin Circuit Description 1 B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR (+) 2 B8 20DG/TN LEFT FRONT WHEEL SPEED SENSOR (-) 2 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR (-) Component Location - 38 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 990 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 991 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Rear Component ID: 450 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Circuit Description 1 B22 18DG/YL REAR WHEEL SPEED SENSOR (-) 2 B222 18DG/WT REAR WHEEL SPEED SENSOR (+) Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 992 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 993 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Rear Component ID: 449 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Circuit Description 1 B3 18DG/YL REAR WHEEL SPEED SENSOR (-) 2 B4 18DG/GY REAR WHEEL SPEED SENSOR (+) Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 994 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 995 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Front Component ID: 451 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Circuit Description 1 B7 20DG/VT RIGHT FRONT WHEEL SPEED SENSOR (+) 2 B6 20DG/WT RIGHT FRONT WHEEL SPEED SENSOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 996 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 997 Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Rear Component ID: 452 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Circuit Description 1 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR (-) 2 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR (+) Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 998 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front Component ID: 448 Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT Color : # of pins : 2 Pin Circuit Description 1 B9 20DG/LG LEFT FRONT WHEEL SPEED SENSOR (+) Pin Circuit Description 1 B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR (+) 2 B8 20DG/TN LEFT FRONT WHEEL SPEED SENSOR (-) 2 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR (-) Component Location - 38 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1001 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1002 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Rear Component ID: 450 Component : SENSOR-WHEEL SPEED-ABS-REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-REAR Color : BLACK # of pins : 2 Qualifier : (EXCEPT ESP) Pin Circuit Description 1 B22 18DG/YL REAR WHEEL SPEED SENSOR (-) 2 B222 18DG/WT REAR WHEEL SPEED SENSOR (+) Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1003 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1004 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Rear Component ID: 449 Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Circuit Description 1 B3 18DG/YL REAR WHEEL SPEED SENSOR (-) 2 B4 18DG/GY REAR WHEEL SPEED SENSOR (+) Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1005 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1006 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Front Component ID: 451 Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT Color : # of pins : 2 Pin Circuit Description 1 B7 20DG/VT RIGHT FRONT WHEEL SPEED SENSOR (+) 2 B6 20DG/WT RIGHT FRONT WHEEL SPEED SENSOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1007 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1008 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Rear Component ID: 452 Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Connector: Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR Color : # of pins : 2 Qualifier : (ESP) Pin Circuit Description 1 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR (-) 2 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR (+) Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 1009 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Description Wheel Speed Sensor: Description and Operation Description DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Description > Page 1012 Wheel Speed Sensor: Description and Operation Operation OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: - Magnetic field strength; the stronger the magnetic field, the stronger the signal - Number of windings in the sensor; more windings provide a stronger signal - Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be - Distance (3) "air gap" between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 in. The assembly plant performs a "Rolls Test" on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 1013 Wheel Speed Sensor: Testing and Inspection REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly. If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool is used to diagnose the RWAL system. For test procedures refer to the ABS Electrical Diagnostic Section. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor - Removal Removal REMOVAL 1. Remove the front rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal . 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. 4500 & 5500 4500 & 5500 1. Remove the front rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal . 2. Remove the wheel speed sensor mounting bolt (1) from the hub. 3. Remove the wheel speed sensor (2) from the hub. 4. Remove the wiring from the clips and disconnect the electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor - Removal > Page 1016 Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor - Installation Installation INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation . 4500 & 5500 4500 & 5500 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub. 3. Install the wheel speed sensor mounting bolt (1) to the hub. Tighten the bolt to 13 Nm (110 in. lbs.). 4. Install the front rotor and brake caliper assembly See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor - Removal > Page 1017 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor - Removal RWAL REAR WHEEL SPEED SENSOR (RWAL) 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). ESP REAR WHEEL SPEED SENSOR (ESP) 1. Raise the vehicle on a hoist. 2. Disconnect the wheel speed sensor electrical connector (3). 3. Remove the mounting bolt (1) from the sensor (4). 4. Remove the sensor (4) from the brake caliper adapter (2). 4500 & 5500 REAR WHEEL SPEED SENSOR - 4500 & 5500 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor - Removal > Page 1018 1. Raise the vehicle on a hoist. 2. Disconnect the sensor wire harness (1). 3. Remove the mounting bolt (3). 4. Remove the sensor (4) from the differential housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor - Removal > Page 1019 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor - Installation RWAL REAR WHEEL SPEED SENSOR (RWAL) 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 in. lbs.). 6. Install the brake line on the sensor stud (2)and install the nut. 7. Lower the vehicle. ESP REAR WHEEL SPEED SENSOR (ESP) 1. Insert the wheel speed sensor (4) in the brake caliper adapter (2). 2. Install the sensor mounting bolt (1) and tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical wiring connector (3) to the sensor (4). 4. Lower the vehicle. 4500 & 5500 REAR WHEEL SPEED SENSOR - 4500 & 5500 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor - Removal > Page 1020 1. Install the O-ring on the sensor (if removed). 2. Insert the sensor (4) in the differential housing. 3. Install the sensor mounting bolt (3) and tighten to 24 Nm (200 in. lbs.). 4. Connect the harness (1) to the sensor (4). Be sure the seal is securely in place between the sensor and the wiring connector. 5. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Yaw Rate Sensor: Locations Component ID: 408 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Circuit Description 1 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 2 D465 20WT/GY DYNAMICS SENSOR HIGH DATA LINK 3 D464 20WT/OR DYNAMICS SENSOR LOW DATA LINK 4-5-6 Z608 20BK/LG GROUND Component Location - 52 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1024 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1025 Yaw Rate Sensor: Diagrams Component ID: 408 Component : SENSOR-DYNAMICS Connector: Name : SENSOR-DYNAMICS Color : # of pins : 6 Pin Circuit Description 1 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 2 D465 20WT/GY DYNAMICS SENSOR HIGH DATA LINK 3 D464 20WT/OR DYNAMICS SENSOR LOW DATA LINK 4-5-6 Z608 20BK/LG GROUND Component Location - 52 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1026 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 1027 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor. The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal Yaw Rate Sensor: Service and Repair Removal REMOVAL 1. Remove the center bezel lower trim panel. 2. Remove the cup holder See: Body and Frame/Interior Moulding / Trim/Drink Holders/Service and Repair/Removal . 3. Disconnect the electrical connector (3) for the dynamics sensor (2). 4. Remove the 3 mounting nuts (1) for the sensor (2). 5. Remove the sensor (2) from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Removal > Page 1030 Yaw Rate Sensor: Service and Repair Installation INSTALLATION 1. Install the dynamics sensor on the mounting studs (2). 2. Install the mounting nuts (1) Tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical connector (3). 4. Install the cup holder. See: Body and Frame/Interior Moulding / Trim/Drink Holders/Service and Repair/Installation . 5. Install the center bezel lower trim panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 Coolant Temperature Sensor/Switch (For Computer): Locations Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1036 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1037 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1038 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1039 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1040 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1041 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1042 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1043 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1044 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1045 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1046 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1047 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1048 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left Cruise Control Switch: Diagrams Switch-Speed Control-Left Component ID: 509 Component : SWITCH-SPEED CONTROL-LEFT Connector: Name : SWITCH-SPEED CONTROL-LEFT Color : BLACK # of pins : 3 A V38 22VT/OR S/C SWITCH NO. 2 SIGNAL B V937 22DB/DG S/C SWITCH RETURN C V37 22VT S/C SWITCH NO. 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Switch-Speed Control-Left > Page 1054 Cruise Control Switch: Diagrams Switch-Speed Control-Right Component ID: 510 Component : SWITCH-SPEED CONTROL-RIGHT Connector: Name : SWITCH-SPEED CONTROL-RIGHT Color : BLACK # of pins : 3 A V38 22VT/OR S/C SWITCH NO. 2 SIGNAL B V937 22DB/DG S/C SWITCH RETURN C V37 22VT S/C SWITCH NO. 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal Cruise Control Switch: Service and Repair Removal REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, if equipped, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Removal > Page 1057 Cruise Control Switch: Service and Repair Installation INSTALLATION 1. Plug electrical connector into switch, or, if equipped, connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten 15 in. lbs. ( 1.7 Nm). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 496 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G6 18VT/GY OIL PRESSURE SIGNAL Pin Circuit Description 1 G6 16VT/GY OIL PRESSURE SIGNAL 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1062 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1063 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1064 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1065 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1066 Oil Pressure Sender: Diagrams Component ID: 496 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G6 18VT/GY OIL PRESSURE SIGNAL Pin Circuit Description 1 G6 16VT/GY OIL PRESSURE SIGNAL 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1067 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1068 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1069 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1070 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure Sensor/Switch - Installation Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor/Switch - Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure Sensor/Switch - Installation > Page 1073 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor/Switch - Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1079 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1080 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1081 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1082 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1083 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1084 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1087 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1088 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1089 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1090 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1091 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1092 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1097 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1098 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1099 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1100 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1101 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1102 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1103 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1104 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1107 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1108 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1109 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1110 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1111 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1112 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1113 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1114 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 1117 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 1120 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component ID 398 Ambient Temperature Sensor / Switch HVAC: Locations Component ID 398 Component ID: 398 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G31 20VT/LG AAT SIGNAL 2 G930 20VT/TN AAT RETURN Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component ID 398 > Page 1126 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component ID 398 > Page 1127 Ambient Temperature Sensor / Switch HVAC: Locations Component ID 402 Component ID: 402 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G31 20VT/LG AAT SIGNAL 2 G930 20VT/TN AAT RETURN Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Component ID 398 > Page 1128 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Component ID 398 Ambient Temperature Sensor / Switch HVAC: Diagrams Component ID 398 Component ID: 398 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G31 20VT/LG AAT SIGNAL 2 G930 20VT/TN AAT RETURN Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Component ID 398 > Page 1131 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Component ID 398 > Page 1132 Ambient Temperature Sensor / Switch HVAC: Diagrams Component ID 402 Component ID: 402 Component : SENSOR-AMBIENT AIR TEMPERATURE Connector: Name : SENSOR-AMBIENT AIR TEMPERATURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G31 20VT/LG AAT SIGNAL 2 G930 20VT/TN AAT RETURN Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Component ID 398 > Page 1133 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Component ID: 411 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Circuit Description 1 C121 20DB/DG SENSOR GROUND 2 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL Component Location - 40 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 1137 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 1138 Evaporator Temperature Sensor / Switch: Diagrams Component ID: 411 Component : SENSOR-EVAPORATOR TEMPERATURE Connector: Name : SENSOR-EVAPORATOR TEMPERATURE Color : NATURAL # of pins : 2 Pin Circuit Description 1 C121 20DB/DG SENSOR GROUND 2 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL Component Location - 40 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 1139 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description Evaporator Temperature Sensor / Switch: Description and Operation Description DESCRIPTION NOTE: Cutaway of HVAC housing shown for clarity. The evaporator temperature sensor (1) is an electrical thermistor located within a molded plastic case that is inserted into the top of the HVAC housing (2) to measure the temperature of the conditioned air downstream of the A/C evaporator (3). Two terminals within the connector receptacle connect the sensor to the vehicle electrical system through a wire lead and connector of the HVAC wire harness. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Description > Page 1142 Evaporator Temperature Sensor / Switch: Description and Operation Operation OPERATION The evaporator temperature sensor monitors the temperature of the conditioned air downstream of the A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C-heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool See: Heating and Air Conditioning/Testing and Inspection/Component Tests and General Diagnostics/Heating-A/C System Diagnostics . The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal Evaporator Temperature Sensor / Switch: Service and Repair Removal REMOVAL NOTE: Illustration shown with instrument panel removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal . 3. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) located on the top of the HVAC housing (3). 4. Remove the evaporator temperature sensor from the HVAC housing by pulling the sensor upward while tipping it forward. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Removal > Page 1145 Evaporator Temperature Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Illustration shown with instrument panel removed for clarity. 1. Install the evaporator temperature sensor (2) into the opening in the top of the HVAC housing (3). Make sure the sensor is fully engage to the housing. 2. Connect the HVAC wire harness (1) to the evaporator temperature sensor. 3. Install the glove box See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation . 4. Reconnect the negative battery cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Component ID: 520 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 C918 18BK/LB A/C PRESSURE GROUND 2 C818 18LB/OR A/C PRESSURE 5 VOLT SUPPLY 3 C18 18LB/BR A/C PRESSURE SIGNAL 4-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1149 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1150 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1151 Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1152 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Circuit Description 1 C918 18BK/LB A/C PRESSURE GROUND Pin Circuit Description 1 C918 20BK/LB A/C PRESSURE GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1153 2 C818 18LB/OR A/C PRESSURE 5 VOLT SUPPLY 2 C818 20LB/OR A/C PRESSURE 5 VOLT SUPPLY 3 C18 18LB/BR A/C PRESSURE SIGNAL 3 C18 20LB/BR A/C PRESSURE SIGNAL 4-Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1154 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1155 Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1156 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1157 Refrigerant Pressure Sensor / Switch: Diagrams Component ID: 520 Component : TRANSDUCER-A/C PRESSURE Connector: Name : TRANSDUCER-A/C PRESSURE Color : BLACK # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 C918 18BK/LB A/C PRESSURE GROUND 2 C818 18LB/OR A/C PRESSURE 5 VOLT SUPPLY 3 C18 18LB/BR A/C PRESSURE SIGNAL 4-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1158 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1159 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1160 Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1161 Connector: Name : TRANSDUCER-A/C PRESSURE Color : GRAY # of pins : 4 Qualifier : (6.7L/GAS) Pin Circuit Description 1 C918 18BK/LB A/C PRESSURE GROUND Pin Circuit Description 1 C918 20BK/LB A/C PRESSURE GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1162 2 C818 18LB/OR A/C PRESSURE 5 VOLT SUPPLY 2 C818 20LB/OR A/C PRESSURE 5 VOLT SUPPLY 3 C18 18LB/BR A/C PRESSURE SIGNAL 3 C18 20LB/BR A/C PRESSURE SIGNAL 4-Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1163 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1164 Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 1165 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description Refrigerant Pressure Sensor / Switch: Description and Operation Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Description > Page 1168 Refrigerant Pressure Sensor / Switch: Description and Operation Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line and its internal resistance changes in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM/ECM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM also prevents the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if found inoperative or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal Refrigerant Pressure Sensor / Switch: Service and Repair Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Removal > Page 1171 Refrigerant Pressure Sensor / Switch: Service and Repair Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer and refrigerant line shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer to 5.1 Nm (45 in. lbs.). 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Front Door Latch - Removal or See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Rear Door Latch - Removal . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Description > Page 1177 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair REMOVAL/INSTALLATION For diesel removal and installation procedures, See Fuel Level Sending Unit/Sensor Removal/Installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Description Outside Temperature Display Sensor: Description and Operation Description DESCRIPTION The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Description > Page 1185 Outside Temperature Display Sensor: Description and Operation Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Totally Integrated Power Module (TIPM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the TIPM. Based upon the resistance in the sensor, the TIPM senses a specific voltage on the temperature sensor signal circuit. The TIPM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 1186 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, and the Totally Integrated Power Module (TIPM). When the sensor is exposed to temperatures above 60° C (140° F), or if the sensor circuit is shorted, 60° C (130/140° F) will appear in the display in place of the temperature. When the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display for Compass Mini - Trip Computer (CMTC) equipped vehicles and - - ° C (- - ° F) will be displayed on Electronic Vehicle Information Center (EVIC) equipped vehicles. The ambient temperature sensor circuit can be diagnosed using the following Temperature System Test, and Sensor Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the Compass Mini - Trip Computer (CMTC), See: Instrument Panel, Gauges and Warning Indicators/Compass/Testing and Inspection or Electronic Vehicle Information Center (EVIC), See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection as applicable. TEMPERATURE SYSTEM TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the On position for readings to meet test specifications. 1. Turn the ignition switch to the Off position. Disconnect the wire harness connector from the ambient temperature sensor. 2. Turn the ignition switch to the On position. The CMTC display should now read - 40° C (- 40° F) or the EVIC display should now read - - ° C (- ° F). If OK, go to STEP 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the Off position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 4. Turn the ignition switch to the On position. The CMTC or EVIC display should now read 60° C (130/140° F). If OK, go to STEP 5. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 5. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the Compass Mini - Trip Computer (CMTC), See: Instrument Panel, Gauges and Warning Indicators/Compass/Testing and Inspection or Electronic Vehicle Information Center (EVIC), See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection as applicable. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 Kohms. At 55° C (130° F), the sensor resistance is 2.488 Kohms. The sensor resistance should read between these two values. If OK, perform further diagnosis of the Compass Mini - Trip Computer (CMTC), See: Instrument Panel, Gauges and Warning Indicators/Compass/Testing and Inspection or Electronic Vehicle Information Center (EVIC), See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection as applicable. If not OK, replace the inoperative ambient temperature sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Removal Outside Temperature Display Sensor: Service and Repair Removal REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Removal > Page 1189 Outside Temperature Display Sensor: Service and Repair Installation INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Component ID: 497 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Circuit Description 1 B25 20DG/WT PARK BRAKE SWITCH SENSE Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1193 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1194 Parking Brake Warning Switch: Diagrams Component ID: 497 Component : SWITCH-PARKING BRAKE Connector: Name : SWITCH-PARKING BRAKE Color : GRAY # of pins : 1 Pin Circuit Description 1 B25 20DG/WT PARK BRAKE SWITCH SENSE Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1195 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Description Parking Brake Warning Switch: Description and Operation Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Description > Page 1198 Parking Brake Warning Switch: Description and Operation Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 1199 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. Refer to appropriate testing. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 3. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch. 4. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Removal Parking Brake Warning Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Removal > Page 1202 Parking Brake Warning Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations Water In Fuel Sensor: Locations Component ID: 447 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A K923 18BR/WT WATER IN FUEL SENSOR GROUND B G123 18VT/LG WATER IN FUEL SENSOR SIGNAL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1206 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1207 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1208 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1209 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1210 Water In Fuel Sensor: Diagrams Component ID: 447 Component : SENSOR-WATER IN FUEL Connector: Name : SENSOR-WATER IN FUEL Color : BLACK # of pins : 2 Qualifier : (5.9L) A K923 18BR/WT WATER IN FUEL SENSOR GROUND B G123 18VT/LG WATER IN FUEL SENSOR SIGNAL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1211 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1212 Connector: Name : SENSOR-WATER IN FUEL Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1213 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 1214 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Description Water In Fuel Sensor: Description and Operation Description DESCRIPTION The Water-In-Fuel (WIF) sensor (2) is located on the bottom of the fuel filter/water separator canister (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Description > Page 1217 Water In Fuel Sensor: Description and Operation Operation OPERATION The sensor sends an input to the Engine Control Module (ECM) when it senses water in the fuel filter/water separator. As the water level in the filter/separator increases, the resistance across the WIF sensor decreases. This decrease in resistance is sent as a signal to the ECM and compared to a high water standard value. Once the value reaches 30 to 40 Kohms, the ECM will activate the water-in-fuel warning lamp through CCD bus circuits. This all takes place when the ignition key is initially put in the ON position. The ECM continues to monitor the input while the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Description and Operation > Page 1218 Water In Fuel Sensor: Service and Repair REMOVAL The Water-In-Fuel (WIF) sensor is located at the bottom of fuel filter/water separator canister. Refer FUEL/WATER SEPARATOR for removal and installation procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Component ID: 481 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Circuit Description 1 Z965 20BK GROUND 2 L10 20WT/GY FUSED IGNITION SWITCH OUTPUT (RUN) Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1223 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1224 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1225 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Circuit Description 1 Z965 20BK GROUND 2 L10 20WT/GY FUSED IGNITION SWITCH OUTPUT (RUN) Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1226 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1227 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1228 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1229 Backup Lamp Switch: Diagrams Component ID: 481 Component : SWITCH-BACKUP LAMP Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (3.7L M/T/4.7L M/T) Pin Circuit Description 1 Z965 20BK GROUND 2 L10 20WT/GY FUSED IGNITION SWITCH OUTPUT (RUN) Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1230 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1231 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1232 Connector: Name : SWITCH-BACKUP LAMP Color : BLACK # of pins : 2 Qualifier : (M/T 5.7L HD/DIESEL M/T) Pin Circuit Description 1 Z965 20BK GROUND 2 L10 20WT/GY FUSED IGNITION SWITCH OUTPUT (RUN) Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1233 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1234 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 1235 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Description Backup Lamp Switch: Description and Operation Description DESCRIPTION Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire switch unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Description > Page 1238 Backup Lamp Switch: Description and Operation Operation OPERATION The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the REVERSE gear has been selected. The switch receives battery voltage through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the ON position. The backup lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation > Page 1239 Backup Lamp Switch: Testing and Inspection BACKUP LAMP SWITCH 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the gear selector lever in any position other than REVERSE, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component ID 478 Brake Light Switch: Locations Component ID 478 Component ID: 478 Component : SWITCH-STOPLAMP Connector: Name : SWITCH-STOPLAMP Color : BLACK # of pins : 6 Pin Circuit Description 1 A103 18GY/RD FUSED B(+) 2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT 4 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 5 Z429 20BK/OR GROUND 6 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component ID 478 > Page 1244 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component ID 478 > Page 1245 Brake Light Switch: Locations Component ID 511 Component ID: 511 Component : SWITCH-STOPLAMP Connector: Name : SWITCH-STOPLAMP Color : BLACK # of pins : 6 Pin Circuit Description 1 A103 18GY/RD FUSED B(+) 2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT 4 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 5 Z429 20BK/OR GROUND 6 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component ID 478 > Page 1246 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Component ID 478 Brake Light Switch: Diagrams Component ID 478 Component ID: 478 Component : SWITCH-STOPLAMP Connector: Name : SWITCH-STOPLAMP Color : BLACK # of pins : 6 Pin Circuit Description 1 A103 18GY/RD FUSED B(+) 2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT 4 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 5 Z429 20BK/OR GROUND 6 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Component ID 478 > Page 1249 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Component ID 478 > Page 1250 Brake Light Switch: Diagrams Component ID 511 Component ID: 511 Component : SWITCH-STOPLAMP Connector: Name : SWITCH-STOPLAMP Color : BLACK # of pins : 6 Pin Circuit Description 1 A103 18GY/RD FUSED B(+) 2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT 4 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 5 Z429 20BK/OR GROUND 6 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL Component Location - 41 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Component ID 478 > Page 1251 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description Brake Light Switch: Description and Operation Description DESCRIPTION The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Description > Page 1254 Brake Light Switch: Description and Operation Operation OPERATION The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned ON and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 1255 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal Brake Light Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (2) near the support bracket on the lower steering column (1). 3. Disconnect the wire harness connector (3) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket. 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Removal > Page 1258 Brake Light Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket on the lower steering column (1). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (2) is firmly seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (4) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (3) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Component ID: 495 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Circuit Description 1 G194 20VT/LG WASH/BEAM SELECT SWITCH SIGNAL 2 L900 20WT/YL WIPER/TURN/BEAM SELECT SWITCH RETURN 3 L12 20WT/OR TURN LAMPS SWITCH SIGNAL 4 W52 20BR/YL INTERMITTENT WIPER SWITCH SIGNAL Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1262 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1263 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1264 Combination Switch: Diagrams Component ID: 495 Component : SWITCH-MULTIFUNCTION Connector: Name : SWITCH-MULTIFUNCTION Color : BLACK # of pins : 4 Pin Circuit Description 1 G194 20VT/LG WASH/BEAM SELECT SWITCH SIGNAL 2 L900 20WT/YL WIPER/TURN/BEAM SELECT SWITCH RETURN 3 L12 20WT/OR TURN LAMPS SWITCH SIGNAL 4 W52 20BR/YL INTERMITTENT WIPER SWITCH SIGNAL Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1265 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1266 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description Combination Switch: Description and Operation Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary WASH position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, LOW speed or HIGH speed; and an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description > Page 1269 Combination Switch: Description and Operation Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the TIPM over the CAN data bus. The TIPM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the WASH mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the wiper motor. The TIPM is programmed to operate the wiper motor at the selected low or high continuous wipe speed, and to provide the selected electronically controlled speed-sensitive intermittent wipe or wipe-after-wash mode features. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Page 1270 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Service and Repair/Removal . 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Airbag - Removal . 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal . 5. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 8. Remove the upper shroud from the lower shroud and the steering column. 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1273 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1274 Combination Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1275 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation . 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Airbag - Installation . 13. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Description Door Switch: Description and Operation Description DESCRIPTION This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Front Door Latch - Removal or See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Rear Door Latch - Removal . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Description > Page 1280 Door Switch: Description and Operation Operation OPERATION The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper electronic door ajar switch status messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Removal Glove Box Lamp Switch: Service and Repair Removal LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Removal > Page 1285 Glove Box Lamp Switch: Service and Repair Installation LAMP/SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Component ID: 489 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Circuit Description 1 L116 20WT/LG HEADLAMP/FOG LAMP SWITCH SIGNAL 2 E2 20OR/BR PANEL LAMPS DIMMER SIGNAL 3 L115 20WT/YL HEADLAMP SWITCH RETURN 4 E19 20OR/BR HEADLAMP SWITCH DIMMER SIGNAL 5 Z407 20BK/OR GROUND 6 L914 20WT/LG CARGO LAMP SWITCH SIGNAL 7-- 8-9-10 - Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1289 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1290 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1291 Headlamp Switch: Diagrams Component ID: 489 Component : SWITCH-HEADLAMP Connector: Name : SWITCH-HEADLAMP Color : BLACK # of pins : 10 Pin Circuit Description 1 L116 20WT/LG HEADLAMP/FOG LAMP SWITCH SIGNAL 2 E2 20OR/BR PANEL LAMPS DIMMER SIGNAL 3 L115 20WT/YL HEADLAMP SWITCH RETURN 4 E19 20OR/BR HEADLAMP SWITCH DIMMER SIGNAL 5 Z407 20BK/OR GROUND 6 L914 20WT/LG CARGO LAMP SWITCH SIGNAL 7-- 8-9-10 - Component Location - 44 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1292 Component Location - 50 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1293 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Description Headlamp Switch: Description and Operation Description DESCRIPTION The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three-position rotary knob (4) for exterior lighting control, a thumbwheel (2) for panel lamps dimming and interior lighting control, and a momentary push button (3) for cargo lamp control. An optional switch has a momentary PUSH function added to the rotary knob for front fog lamp control. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. The thumbwheel is also plastic and knurled. On vehicles with optional fog lamps the rotary knob also has the text PUSH and an International Control and Display Symbol icon for Front Fog Light applied to it. The cargo lamp push button is plastic with a smooth finish and the text CARGO applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if ineffective or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Description > Page 1296 Headlamp Switch: Description and Operation Operation OPERATION The headlamp switch uses two resistor multiplexed outputs and one conventional output to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions, and on a cargo lamp return circuit to control the cargo lamps. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Cargo Lamps Control - The cargo lamp push button on the headlamp switch is depressed to activate or deactivate the cargo lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate cargo lighting control outputs through its internal cargo lamp driver circuit. Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM responds by energizing or de-energizing the front fog lamps and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the park lamp and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The TIPM also remembers which headlamp beams were last selected with the multi-function switch, and energizes those beams by default the next time the headlamps are turned ON. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome DEFEAT, dome ON, PARADE mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 1297 Headlamp Switch: Testing and Inspection HEADLAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Remove the cluster bezel from the instrument panel See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Removal and Replacement/Instrument Panel Cluster Bezel - Removal . 2. Disconnect the wire harness connector from the back of the headlamp switch. 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective headlamp switch as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Removal Headlamp Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel (1) from the instrument panel. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Removal and Replacement/Instrument Panel Cluster Bezel - Removal . 3. Disconnect the wire harness connector (3) from the back of the headlamp switch (4). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (2) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Removal > Page 1300 Headlamp Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the headlamp switch (4) to the back of the cluster bezel (1). 2. Install and tighten the three screws (2) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 Nm (20 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector (3) to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Removal and Replacement/Instrument Panel Cluster Bezel - Installation . 5. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Horn Switch: Diagrams Component ID: 493 Component : SWITCH-HORN Connector: Name : SWITCH-HORN Color : WHITE # of pins : 2 Pin Circuit Description 1 X3 20DG/VT HORN SWITCH SENSE 2-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1309 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1310 Accelerator Pedal Position Sensor: Diagrams Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1311 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 1314 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 1317 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1321 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1322 Air Flow Meter/Sensor: Diagrams Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1323 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1324 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 1327 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1331 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1332 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1333 Battery Temperature Sensor: Diagrams Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1334 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1335 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 1338 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20°F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 1341 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1345 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1346 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1347 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1348 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1349 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1350 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1351 Camshaft Position Sensor: Diagrams Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1352 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1353 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1354 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1355 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1356 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1357 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 1360 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor o-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 1363 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor o-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 Coolant Temperature Sensor/Switch (For Computer): Locations Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1367 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1368 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1369 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1370 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1371 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1372 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1373 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1374 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1375 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1376 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1377 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1378 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1379 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 1384 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) for the CKP is located behind the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 1387 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1391 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1392 Crankcase Pressure Sensor: Diagrams Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1393 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1398 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1399 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1400 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1401 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1402 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1403 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1404 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1405 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1408 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1409 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1410 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1411 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1412 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1413 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1414 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1415 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 1418 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 1421 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1426 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1427 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1428 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1429 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1430 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 1431 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1434 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1435 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1436 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1437 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1438 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 1439 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 1443 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 1444 High Idle Switch: Diagrams Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 1445 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1450 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1451 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1452 Intake Air Temperature Sensor: Connector Locations Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1453 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1454 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1455 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1456 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1457 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1458 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 421 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1461 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1462 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1463 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K21 20DB/LG IAT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1464 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1465 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1466 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1467 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1468 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1469 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1470 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1471 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1472 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1473 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1474 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1475 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 1476 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 1477 Intake Air Temperature Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 1480 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 1485 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 1486 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 1487 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 1488 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 1489 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 1490 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 1491 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Map Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 1492 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 1493 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 1496 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 1497 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 1498 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 1499 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 1500 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 1501 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 1502 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Map Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 1503 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 1504 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Air Pressure (MAP) Sensor Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Air Pressure (MAP) Sensor DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Air Pressure (MAP) Sensor > Page 1507 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1510 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1511 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1512 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1521 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1522 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1523 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1524 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1525 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1526 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1527 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1533 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1534 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1535 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1545 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1546 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1547 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1552 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1553 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1554 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1555 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1556 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1557 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1558 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1568 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1569 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 1570 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1580 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1581 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1582 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1583 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1584 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1585 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 1586 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 431 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1589 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1590 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1591 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1592 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1593 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1594 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1595 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1596 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 Z42 20BK/LG GROUND 3 K902 20BR/DG O2 RETURN (UPSTREAM) 4 K41 20DB/LB O2 1/1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1597 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1598 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1599 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1600 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1601 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 432 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1602 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1603 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1604 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1605 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1606 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1607 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 2 Z43 20BK/LB GROUND 3 K904 20DB/DG O2 RETURN (DOWNSTREAM) 4 K141 20DB/YL O2 1/2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1608 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1609 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 1610 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 209 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 3 D132 20WT DIAGNOSTIC PORT LOW DATA LINK 4 K141 20DB/YL O2 1/2 SIGNAL 5 K734 20BR/DG 02 1/2 PUMP CURRENT 6 K41 20DB/LB O2 1/1 SIGNAL 7 K89 20BR/LG 02 1/1 PUMP CURRENT 8 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 9 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 10 Z902 20BK GROUND 11 D133 20WT/OR DIAGNOSTIC PORT HIGH DATA LINK 12 K904 20DB/DG O2 1/2 RETURN 13 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 14 K902 20BR/DG O2 1/1 RETURN 15 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 16 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1613 Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 3 D132 20WT DIAGNOSTIC PORT LOW DATA LINK 4 K141 20DB/YL O2 1/2 SIGNAL 5 K734 20BR/DG 02 1/2 PUMP CURRENT 6 K41 20DB/LB O2 1/1 SIGNAL 7 K89 20BR/LG 02 1/1 PUMP CURRENT 8 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 9 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 10 Z902 20BK GROUND 11 D133 20WT/OR DIAGNOSTIC PORT HIGH DATA LINK 12 K904 20DB/DG O2 1/2 RETURN 13 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 14 K902 20BR/DG O2 1/1 RETURN 15 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 16 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1614 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 431 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1615 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1616 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1617 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1618 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1619 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1620 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1621 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1622 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 Z42 20BK/LG GROUND 3 K902 20BR/DG O2 RETURN (UPSTREAM) 4 K41 20DB/LB O2 1/1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1623 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1624 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1625 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1626 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1627 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 432 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1628 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1629 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1630 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1631 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1632 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1633 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 2 Z43 20BK/LB GROUND 3 K904 20DB/DG O2 RETURN (DOWNSTREAM) 4 K141 20DB/YL O2 1/2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1634 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1635 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 1636 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 1639 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 1640 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 1643 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 1644 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal.DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 1649 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1654 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1655 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1656 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1657 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1658 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1659 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1660 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1661 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1662 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1663 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 1664 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1667 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1668 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1669 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1670 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1671 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1672 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1673 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1674 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1675 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1676 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 1677 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 1680 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 1681 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 1682 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 1683 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 1686 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 1687 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 1688 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 1689 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1694 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1695 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1696 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1697 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1698 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1699 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1700 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1701 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1702 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1703 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1704 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1705 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1706 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1707 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1708 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 1709 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1715 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1716 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1717 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1718 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1719 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1720 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1721 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 1722 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1725 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1726 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1727 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1728 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1729 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1730 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1731 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 1732 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 1735 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 1738 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1742 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1743 Crankcase Pressure Sensor: Diagrams Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 1744 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 409 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K935 18DB EGR TEMPERATURE SENSOR SIGNAL Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K935 18DB EGR TEMPERATURE SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 1750 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1753 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. 4. Unscrew nut (2) at intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1754 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1755 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1756 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 1757 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). PRESSURE DIFFERENTIAL TUBING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 1763 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 1764 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION PRESSURE DIFFERENTIAL TUBING 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 1765 NOTE: Make sure there is not a dip in the pressure differential hoses. 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 1770 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1775 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1776 Accelerator Pedal Position Sensor: Diagrams Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1777 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 1780 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 1783 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1787 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1788 Air Flow Meter/Sensor: Diagrams Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1789 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1790 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 1793 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations Component ID: 419 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 K915 18BR/WT FUEL RAIL SENSOR RETURN Pin Circuit Description 1 K916 18BR/OR SENSOR GROUND 2 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 3 F855 18PK/YL 5 VOLT SUPPLY Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1797 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1798 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1799 Fuel Pressure Sensor/Switch: Diagrams Component ID: 419 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 K915 18BR/WT FUEL RAIL SENSOR RETURN Pin Circuit Description 1 K916 18BR/OR SENSOR GROUND 2 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 3 F855 18PK/YL 5 VOLT SUPPLY Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1800 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1801 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1802 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 1805 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 1806 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components. 8. Start engine and check for fuel leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 1810 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 1811 High Idle Switch: Diagrams Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 1812 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Component ID: 446 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 2 K541 18BR/VT TURBO SPEED SENSOR GROUND Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 1816 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 1817 Turbo Boost Sensor: Diagrams Component ID: 446 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 2 K541 18BR/VT TURBO SPEED SENSOR GROUND Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 1818 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal Turbo Boost Sensor: Service and Repair Removal REMOVAL CAUTION: Do not use a screw driver or tool to pry sensor out of the turbocharger bearing housing. Damage to sensor may result. If sensor is damaged during removal, install a new sensor. 1. Disconnect negative battery cable. 2. Remove turbocharger oil supply line. 3. Disconnect speed sensor electrical connector. 4. Remove turbocharger speed sensor mounting bolt (1). 5. Remove turbocharger speed sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal > Page 1821 Turbo Boost Sensor: Service and Repair Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). 4. Connect speed sensor electrical connector. 5. Install turbocharger oil supply line. Tighten fitting to 24 Nm (18 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1826 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1827 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1828 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1829 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1830 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1831 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1832 Camshaft Position Sensor: Diagrams Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1833 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1834 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1835 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1836 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1837 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1838 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 1841 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor o-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 1844 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor o-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 1849 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) for the CKP is located behind the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 1852 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 1858 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Component ID: 498 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Circuit Description 1 R106 20LG/LB PASSENGER AIRBAG MUX SWITCH SENSE 2 R104 20LB/LG PASSENGER AIRBAG MUX SWITCH RETURN 3 G104 20VT/GY PASSENGER AIRBAG INDICATOR DRIVER 4 F201 20PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START) 5-6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1863 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1864 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1865 Air Bag Deactivation Switch: Diagrams Component ID: 498 Component : SWITCH-PASSENGER AIRBAG ON/OFF Connector: Name : SWITCH-PASSENGER AIRBAG ON/OFF Color : BLACK # of pins : 6 Pin Circuit Description 1 R106 20LG/LB PASSENGER AIRBAG MUX SWITCH SENSE 2 R104 20LB/LG PASSENGER AIRBAG MUX SWITCH RETURN 3 G104 20VT/GY PASSENGER AIRBAG INDICATOR DRIVER 4 F201 20PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START) 5-6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1866 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 1867 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description Air Bag Deactivation Switch: Description and Operation Description DESCRIPTION The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this vehicle (except light-duty DR 1500) equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral amber Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of the instrument panel center bezel, near the center of the instrument panel. When the switch is in its installed position, the only components visible through the dedicated opening of the center bezel are the switch bezel (2) and lens, the nomenclature imprinted on the lens, and the key cylinder actuator (3). The OFF position nomenclature of the switch is illuminated and visible only when that switch position is selected. The ON position of the switch is neither visible or illuminated but can be determined by the orientation of the slot of the key cylinder actuator. The remainder of the switch is concealed behind the switch bezel and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch bezel with three small screws. The molded plastic switch bezel also has three integral mounting tabs that are used to secure the switch and bezel unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if ineffective or damaged, the switch must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Description > Page 1870 Air Bag Deactivation Switch: Description and Operation Operation OPERATION The passenger airbag on/off switch allows the customer to turn the passenger airbag function ON or OFF to accommodate certain uses of the right front seating position where airbag protection may not be desired. The OFF indicator of the switch will be illuminated whenever the switch is turned to the OFF position and the ignition switch is in the ON position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring-loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the OFF nomenclature), the OFF indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position) the OFF indicator will be extinguished and the passenger airbag is enabled. The OFF indicator and the enabling or disabling of the passenger airbag is controlled electronically by the Occupant Restraint Controller (ORC) based upon inputs it receives from the on/off switch. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the ORC. The ORC continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the OFF position, the ORC provides a ground input to the OFF indicator through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the indicator. The ORC will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or OFF indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. The hard wired circuits between the passenger airbag on/off switch and the ORC may be diagnosed using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the passenger airbag on/off switch or the electronic controls and communication between other modules and devices that provide some features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the passenger airbag on/off switch or the electronic controls and communication related to passenger airbag on/off switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal Air Bag Deactivation Switch: Service and Repair Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles (except light-duty DR 1500) equipped with dual front airbags. Quad cab, mega cab and light-duty DR 1500 standard cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Center Bezel - Removal . 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel. 4. Remove the passenger airbag on/off switch and bezel from the center bezel as a unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Service and Repair > Removal > Page 1873 Air Bag Deactivation Switch: Service and Repair Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A passenger airbag on/off switch is used only on standard cab vehicles (except light-duty DR 1500) equipped with dual front airbags. Quad cab, mega cab and light-duty DR 1500 standard cab vehicles have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. 1. Position the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch bezel to the back of the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Center Bezel - Installation . 4. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left Impact Sensor: Locations Sensor-Front Impact-Left Component ID: 417 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 R81 20LB/WT LEFT FRONT IMPACT SENSOR GROUND 2 R79 20LB/VT LEFT FRONT IMPACT SENSOR SIGNAL Component Location - 30 Fig.30-Left Engine Compartment Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1878 Impact Sensor: Locations Sensor-Front Impact-Right Component ID: 418 Component : SENSOR-FRONT IMPACT-RIGHT Connector: Name : SENSOR-FRONT IMPACT-RIGHT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 R82 20WT/LB RIGHT FRONT IMPACT SENSOR GROUND 2 R80 20VT/LB RIGHT FRONT IMPACT SENSOR SIGNAL Component Location - 29 Fig. 29-Right Side Engine Compartment Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1879 Impact Sensor: Locations Sensor-Side Impact-Left 1 Component ID: 438 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Circuit Description 1 R13 20LG/TN LEFT SIDE IMPACT SENSOR 1 SIGNAL 2 R15 20LG/BR LEFT SIDE IMPACT SENSOR 1 GROUND 3-4-Component Location - 58 Fig. 58-Left Side Body (Standard Cab) Component Location - 63 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1880 Fig. 63-Left Side Body (Quad Cab/Mega Cab) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1881 Impact Sensor: Locations Sensor-Side Impact-Right 1 Component ID: 439 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Circuit Description 1 R14 20TN/LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL 2 R16 20BR/LG RIGHT SIDE IMPACT SENSOR 1 GROUND 3-4-Component Location - 61 Fig. 61-Right Side Body (Standard Cab) Component Location - 64 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Sensor-Front Impact-Left > Page 1882 Fig. 64-Right Side Body (Quad Cab/Mega Cab) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left Impact Sensor: Diagrams Sensor-Front Impact-Left Component ID: 417 Component : SENSOR-FRONT IMPACT-LEFT Connector: Name : SENSOR-FRONT IMPACT-LEFT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 R81 20LB/WT LEFT FRONT IMPACT SENSOR GROUND 2 R79 20LB/VT LEFT FRONT IMPACT SENSOR SIGNAL Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1885 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1886 Impact Sensor: Diagrams Sensor-Front Impact-Right Component ID: 418 Component : SENSOR-FRONT IMPACT-RIGHT Connector: Name : SENSOR-FRONT IMPACT-RIGHT Color : YELLOW # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 R82 20WT/LB RIGHT FRONT IMPACT SENSOR GROUND 2 R80 20VT/LB RIGHT FRONT IMPACT SENSOR SIGNAL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1887 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1888 Impact Sensor: Diagrams Sensor-Side Impact-Left 1 Component ID: 438 Component : SENSOR-SIDE IMPACT-LEFT 1 Connector: Name : SENSOR-SIDE IMPACT-LEFT 1 Color : YELLOW # of pins : 4 Pin Circuit Description 1 R13 20LG/TN LEFT SIDE IMPACT SENSOR 1 SIGNAL 2 R15 20LG/BR LEFT SIDE IMPACT SENSOR 1 GROUND 3-4-Component Location - 58 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1889 Component Location - 63 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1890 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1891 Impact Sensor: Diagrams Sensor-Side Impact-Right 1 Component ID: 439 Component : SENSOR-SIDE IMPACT-RIGHT 1 Connector: Name : SENSOR-SIDE IMPACT-RIGHT 1 Color : YELLOW # of pins : 4 Pin Circuit Description 1 R14 20TN/LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL 2 R16 20BR/LG RIGHT SIDE IMPACT SENSOR 1 GROUND 3-4-Component Location - 61 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1892 Component Location - 64 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Sensor-Front Impact-Left > Page 1893 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Description Impact Sensor: Description and Operation Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front impact sensor is secured with a screw to the back of the right or left end of the lower radiator crossmember within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Two side impact sensors (1) are used on this vehicle when it is equipped with the optional side curtain airbags, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Description > Page 1896 Impact Sensor: Description and Operation Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through left or right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal Impact Sensor: Service and Repair Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left end of the lower radiator crossmember (1). 3. Disconnect the headlamp and dash wire harness connector (2) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1899 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (4) to the inner B-pillar (2). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (1) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1900 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt and Retractor - Removal . 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1901 Impact Sensor: Service and Repair Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. 1. Position the right or left front impact sensor (3) into the engine compartment. 2. Reconnect the headlamp and dash wire harness connector (2) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left end of the lower radiator crossmember (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the crossmember. 4. Install and tighten the screw (4) that secures the sensor to the back of the crossmember. Tighten the screw to 10 Nm (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests . Side - Mega Cab SIDE - MEGA CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1902 1. Position the side impact sensor (4) to the large hole above the retractor mounting hole in the inner B-pillar (2). 2. Reconnect the body wire harness connector (1) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests . Side - Quad Cab SIDE - QUAD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Removal > Page 1903 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests . Side - Standard Cab SIDE - STANDARD CAB WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 Nm (70 in. lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt and Retractor - Installation . 6. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Component ID: 506 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Circuit Description 1 Z951 18BK GROUND 2 G10 20VT/LG SEAT BELT SWITCH SENSE Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1907 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Circuit Description 1 Z917 20BK GROUND 2 R57 20LG/GY DRIVER SEAT BELT SWITCH SENSE Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1908 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1909 Seat Belt Buckle Switch: Diagrams Component ID: 506 Component : SWITCH-SEAT BELT-DRIVER Connector: Name : SWITCH-SEAT BELT-DRIVER Color : # of pins : 2 Qualifier : (HD) Pin Circuit Description 1 Z951 18BK GROUND 2 G10 20VT/LG SEAT BELT SWITCH SENSE Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1910 Connector: Name : SWITCH-SEAT BELT-DRIVER Color : LT. GRAY # of pins : 2 Qualifier : (LD) Pin Circuit Description 1 Z917 20BK GROUND 2 R57 20LG/GY DRIVER SEAT BELT SWITCH SENSE Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1911 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description Seat Belt Buckle Switch: Description and Operation Description DESCRIPTION All vehicles are equipped with a driver side seat belt switch that is a small, normally open, single pole, single throw, leaf contact, momentary switch. The driver side seat belt switch is integral to the buckle (1) of the driver side front seat belt buckle, which is located on a stamped steel stanchion secured by a screw (3) to the inboard side of the driver side front seat cushion frame. The seat belt switch is connected to the vehicle electrical system through a two-lead pigtail wire and connector (4) on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired. If ineffective or damaged, the entire driver side front seat belt buckle-half unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Description > Page 1914 Seat Belt Buckle Switch: Description and Operation Operation OPERATION The driver side seat belt switch is designed to control a path to ground for the seat belt switch sense input of the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Seat Sensor/Switch: Locations Component ID: 437 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Circuit Description 1 R261 20LB/TN DRIVER SEAT POSITION SENSOR DATA 2 R263 20LB/GY DRIVER SEAT POSITION SENSOR VOLTAGE Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1918 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1919 Seat Sensor/Switch: Diagrams Component ID: 437 Component : SENSOR-SEAT TRACK POSITION-DRIVER Connector: Name : SENSOR-SEAT TRACK POSITION-DRIVER Color : DK. GRAY # of pins : 2 Qualifier : (EXCEPT HEATED SEATS) Pin Circuit Description 1 R261 20LB/TN DRIVER SEAT POSITION SENSOR DATA 2 R263 20LB/GY DRIVER SEAT POSITION SENSOR VOLTAGE Component Location - 66 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1920 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1925 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1926 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1927 Battery Temperature Sensor: Diagrams Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1928 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1929 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 1932 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20°F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 1935 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component ID 472 Clutch Switch: Locations Component ID 472 Component ID: 472 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component ID 472 > Page 1940 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component ID 472 > Page 1941 Clutch Switch: Locations Component ID 482 Component ID: 482 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Component ID 472 > Page 1942 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Component ID 472 Clutch Switch: Diagrams Component ID 472 Component ID: 472 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Component ID 472 > Page 1945 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Component ID 472 > Page 1946 Clutch Switch: Diagrams Component ID 482 Component ID: 482 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams > Component ID 472 > Page 1947 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 1953 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock Neutral Safety Switch: Locations Switch-Clutch Interlock Component ID 472 Component ID: 472 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 1958 Component ID 482 Component ID: 482 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 1959 Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 1960 Neutral Safety Switch: Locations Switch-Clutch Interlock/Upstop Component ID: 483 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Circuit Description 1-2-3 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 4 Z993 18BK GROUND 5-6-- Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Switch-Clutch Interlock > Page 1961 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock Neutral Safety Switch: Diagrams Switch-Clutch Interlock Component ID 472 Component ID: 472 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 1964 Component ID 482 Component ID: 482 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 1965 Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 1966 Neutral Safety Switch: Diagrams Switch-Clutch Interlock/Upstop Component ID: 483 Component : SWITCH-CLUTCH INTERLOCK/UPSTOP Connector: Name : SWITCH-CLUTCH INTERLOCK/UPSTOP Color : # of pins : 6 Qualifier : (6.7L) Pin Circuit Description 1-2-3 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 4 Z993 18BK GROUND 5-6-- Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Switch-Clutch Interlock > Page 1967 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams > Component ID 473 Suspension Mode Switch: Diagrams Component ID 473 Component ID: 473 Component : SWITCH-DISCONNECTING STABILIZER BAR Connector: Name : SWITCH-DISCONNECTING STABILIZER BAR Color : BLACK # of pins : 12 Pin Circuit Description 1 T537 20YL/LG LOCKER SWITCH SUPPLY 2 T535 20YL/BR LOCKER SWITCH SENSE 3 T531 20YL/TN STABILIZER BAR SWITCH SENSE 4 T536 20YL/WT SWITCH SUPPLY 5 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE 6 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE 7 T534 20YL LOCKER FR/RR ILLUMINATION SENSE 8 T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE 9 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE 10 - 11 E11 20OR/DB PANEL LAMPS DRIVER 12 Z952 20BK GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Diagrams > Component ID 473 > Page 1974 Suspension Mode Switch: Diagrams Component ID 484 Component ID: 484 Component : SWITCH-DISCONNECTING STABILIZER BAR Connector: Name : SWITCH-DISCONNECTING STABILIZER BAR Color : BLACK # of pins : 12 Pin Circuit Description 1 T537 20YL/LG LOCKER SWITCH SUPPLY 2 T535 20YL/BR LOCKER SWITCH SENSE 3 T531 20YL/TN STABILIZER BAR SWITCH SENSE 4 T536 20YL/WT SWITCH SUPPLY 5 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE 6 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE 7 T534 20YL LOCKER FR/RR ILLUMINATION SENSE 8 T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE 9 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE 10 - 11 E11 20OR/DB PANEL LAMPS DRIVER 12 Z952 20BK GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is not recommended for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants may clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: It is not recommended to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor (6) must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a GREEN sensor body, with (an triangle insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. For car applications, there is a 315 MHz TPM sensor with a Black sensor body with an oval insignia. NOTE: This vehicle uses the 315 MHz TPM sensor with the GREEN sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues.) The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 1981 Tire Pressure Sensor: Description and Operation Operation OPERATION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, nut, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The High Pressure TPM sensor can be in one of the following modes: Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 2 psi (13.8 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 2 psi (13.8 kPA) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 Block Mode - If the vehicle has not been moving for more then 20 minutes, or if the sensor's mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After 8 minutes of continuous driving above 15 mph (24 km/h), the TPM sensor will change to DRIVE MODE. Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Page 1982 Tire Pressure Sensor: Testing and Inspection TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. NOTE: Tire pressure will vary with temperature by about 1 psi (6.9 kPa) for every 12 F (6.5 C). This means that when the outside temperature decreases, the tire pressure will also decrease. Tire pressure should always be set based on cold inflation tire pressure. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire on the vehicle, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for leaks around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. If the indicator lamp is flashing on/off for 75 seconds and then remains on solid, a system fault was detected. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove the tire and wheel assembly. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Let the air out of the tire. 4. Remove the nut (3). 5. Push the sensor into the tire (1) (so the sensor is loose inside the tire). 6. Remove the tire from the rim. 7. Retrieve the sensor (1) from the tire. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1985 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor (6), replace valve cap (2), nut (3), valve core and sensor seal (4) to ensure proper sealing. NOTE: The notch/flat should be lined up together and facing towards the wheel during installation. 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Damage to the sensor may occur if the sensor is installed incorrectly. NOTE: A flat on the seal seat is used to key the seat to the sensor housing. The notch/flat should be lined up together and facing towards the wheel during installation. 3. Install sensor nut (3) and hand tighten. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-tightening the sensor to as much as 10 Nm (88 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturer's instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 1986 Rotating Wheel Tire Changers- Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 180° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 180° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement 8. Lower vehicle. 9. If the vehicle has been stationary for more then 20 minutes, drive the vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. A new sensor ID can also be programmed directly into the WCM by using a RKE-TPM Analyzer in conjunction with a Scan Tool. Once the new sensor ID has been programmed, the RKE-TPM Analyzer can be used to update the TPMS by activating the sensor. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations Tire Pressure Warning Reset Switch: Locations Component ID: 513 Component : SWITCH-TIRE PRESSURE MONITOR Connector: Name : SWITCH-TIRE PRESSURE MONITOR Color : BROWN # of pins : 6 Pin Circuit Description 1 G561 20VT TPM INDICATOR CONTROL 2 E11 20OR/DB PANEL LAMPS DRIVER 3 G562 20VT/YL TPM SWITCH SIGNAL 4 Z600 20BK GROUND 5 F504 20GY/PK NO FUNCTION DEFINED 6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 1990 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 1991 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 1992 Tire Pressure Warning Reset Switch: Diagrams Component ID: 513 Component : SWITCH-TIRE PRESSURE MONITOR Connector: Name : SWITCH-TIRE PRESSURE MONITOR Color : BROWN # of pins : 6 Pin Circuit Description 1 G561 20VT TPM INDICATOR CONTROL 2 E11 20OR/DB PANEL LAMPS DRIVER 3 G562 20VT/YL TPM SWITCH SIGNAL 4 Z600 20BK GROUND 5 F504 20GY/PK NO FUNCTION DEFINED 6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 1993 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1999 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2000 Fluid Pressure Sensor/Switch: Diagrams Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 2001 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 2004 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 2007 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 2011 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 2012 Overdrive Switch: Diagrams Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 2013 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 2014 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2017 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2018 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2019 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2020 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2021 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2022 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2023 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description Shift Solenoid Position Sensor/Switch: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description > Page 2028 Shift Solenoid Position Sensor/Switch: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 545RFE PRESSURE SWITCH STATES: A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal Shift Solenoid Position Sensor/Switch: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Powertrain Management/Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal > Page 2031 Shift Solenoid Position Sensor/Switch: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2036 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2037 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2038 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2039 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2040 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2041 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2042 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2043 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2044 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2045 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 2046 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2049 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2050 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2051 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2052 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2053 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2054 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2055 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2056 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2057 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2058 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 2059 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2062 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2063 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2064 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 2065 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 2068 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 2069 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 2070 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 2071 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2076 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2077 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2078 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2079 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2080 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2081 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2082 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2083 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2084 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2085 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2086 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2087 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2088 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2089 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2090 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2091 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2092 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2093 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2094 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2095 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2096 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2097 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2098 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2099 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2100 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2101 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2102 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2103 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2104 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2105 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2106 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2107 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2108 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2109 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2110 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2111 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 2112 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2115 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2116 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2117 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2118 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2119 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2120 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2121 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2122 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2123 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2124 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2125 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2126 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2127 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2128 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2129 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2130 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2131 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2132 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2133 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2134 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2135 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2136 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2137 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2138 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2139 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2140 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2141 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2142 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2143 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2144 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2145 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2146 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2147 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2148 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2149 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2150 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 2151 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2154 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 2155 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2158 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2159 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2160 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2161 INPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 2165 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 2166 Transmission Temperature Sensor/Switch: Diagrams Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 2167 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description Transmission Temperature Sensor/Switch: Description and Operation Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 2170 Transmission Temperature Sensor/Switch: Description and Operation Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 > Service and Repair > 48RE Automatic Transmission Transmission Temperature Sensor/Switch: Service and Repair 48RE Automatic Transmission Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 > Service and Repair > 48RE Automatic Transmission > Page 2173 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 > Service and Repair > 48RE Automatic Transmission > Page 2174 Transmission Temperature Sensor/Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 > Service and Repair > 48RE Automatic Transmission > Page 2175 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) 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 > Service and Repair > 48RE Automatic Transmission > Page 2176 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 515 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Circuit Description 1 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT 2-3 K977 20BR/WT MODE SELECT 4 E11 20OR/DB PANEL LAMPS CONTROL 5 Z905 20BK GROUND 6 G95 20VT/BR NEUTRAL INDICATOR 7 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2185 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2186 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2187 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2188 Four Wheel Drive Selector Switch: Diagrams Component ID: 515 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Circuit Description 1 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT 2-3 K977 20BR/WT MODE SELECT 4 E11 20OR/DB PANEL LAMPS CONTROL 5 Z905 20BK GROUND 6 G95 20VT/BR NEUTRAL INDICATOR 7 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2189 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2190 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 2191 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2194 - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Powertrain Management/Transmission Control Systems/Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2195 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and , T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Powertrain Management/Transmission Control Systems/Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2196 Module/Description and Operation/Operation is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2197 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and , T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Powertrain Management/Transmission Control Systems/Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2198 Module/Description and Operation/Operation is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2199 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 2200 - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Powertrain Management/Transmission Control Systems/Relays and Modules Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2205 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2206 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2207 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2208 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2209 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2210 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2211 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 443 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC EXCEPT POWER WAGON) Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A 2 Z955 20BK GROUND 2 Z955 18BK GROUND 2 Z901 20BK GROUND Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2212 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2213 Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC POWER WAGON) Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2214 2 G180 18VT/YL SENSOR RETURN 2 G180 20VT/YL SENSOR RETURN Component Location - 22 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 2215 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID 14 Component ID: 14 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2218 Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component ID 18 Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2219 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2220 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2221 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2222 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2223 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2224 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2225 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 443 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC EXCEPT POWER WAGON) Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A 2 Z955 20BK GROUND 2 Z955 18BK GROUND 2 Z901 20BK GROUND Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2226 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2227 Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC POWER WAGON) Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2228 2 G180 18VT/YL SENSOR RETURN 2 G180 20VT/YL SENSOR RETURN Component Location - 22 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 2229 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2232 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2233 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2234 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Position Sensor Linear Movement During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2235 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2236 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2237 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 2238 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 2241 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the o-ring seal on the transfer case position sensor. Replace the o-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 435 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN 2 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 2246 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 2247 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 436 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T70 20YL INPUT SPEED SENSOR 1 (N2) SIGNAL 2 T341 20DG/VT INPUT SPEED SENSOR 1 (N2) RETURN Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 2248 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 435 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN 2 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 2251 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 2252 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 436 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T70 20YL INPUT SPEED SENSOR 1 (N2) SIGNAL 2 T341 20DG/VT INPUT SPEED SENSOR 1 (N2) RETURN Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 2253 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 2256 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description Heated Glass Element Switch: Description and Operation Description DESCRIPTION The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is pressed to ON, a request signal is sent on the CAN-B Bus to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the totally integrated power module (TIPM) is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors. The grid lines heat the glass to help clear the surface of fog or frost. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Description > Page 2262 Heated Glass Element Switch: Description and Operation Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors. NOTE: The EBL system turns off automatically after 15 minutes of initial operation. Each following activation cycle of the EBL system will last 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes, as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will automatically shut off if the ignition switch is turned to any position other than RUN, or it can be turned off manually by pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and the rear window defogger indicator cannot be repaired and the A/C-heater control must be replaced if found inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C Heater Control - Removal . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite Power Window Switch: Locations Switch-Power Sliding Backlite Component ID: 499 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Circuit Description 1-2 Z974 12BK GROUND 3 Z975 12BK GROUND 4 F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 5 Q950 12OR/LG POWER BACKLITE OPEN (+) 6 P301 20LG/OR PANEL LAMPS DRIVER 7 Z976 20BK GROUND 8 Q951 12OR/VT POWER BACKLITE OPEN (-) Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2267 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2268 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2269 Power Window Switch: Locations Switch-Power Window-Left Rear Component ID: 500 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Circuit Description 1 Q111 14TN/YL DRIVER REAR WINDOW DRIVER (UP) Pin Circuit Description 1 Q211 14TN/LB DRIVER REAR WINDOW DRIVER (DOWN) 2 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN) 3-4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP) 5 Q211 14TN/LB DRIVER REAR WINDOW DRIVER (DOWN) 5 Q111 14TN/YL DRIVER REAR WINDOW DRIVER (UP) 6 Q15 14OR/LB POWER WINDOW SWITCH FEED Component Location - 57 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2270 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2271 Power Window Switch: Locations Switch-Power Window-Passenger Component ID: 501 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Circuit Description 1 Q12 12OR/BR RIGHT FRONT WINDOW DRIVER (UP) 2 Q26 12OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN) 3-4 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP) 5 Q22 12OR/VT RIGHT FRONT WINDOW DRIVER (DOWN) 6 Q15 12OR/LB POWER WINDOW SWITCH FEED Component Location - 56 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2272 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2273 Power Window Switch: Locations Switch-Power Window-Right Rear Component ID: 502 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Circuit Description 1 Q112 14TN/YL PASSENGER REAR WINDOW DRIVER (UP) Pin Circuit Description 1 Q212 14TN/LB PASSENGER REAR WINDOW DRIVER (DOWN) 2 Q612 14OR/GY RIGHT REAR WINDOW DRIVER (DOWN) 3-4 Q412 14OR/WT RIGHT REAR WINDOW DRIVER (UP) 5 Q212 14TN/LB PASSENGER REAR WINDOW DRIVER (DOWN) 5 Q112 14TN/YL PASSENGER REAR WINDOW DRIVER (UP) 6 Q15 14TN/LG POWER WINDOW SWITCH FEED Component Location - 57 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2274 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2275 Power Window Switch: Locations Switch-Window/Door Lock-Driver Component ID: 518 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Circuit Description 1 Q612 14OR/DB RIGHT REAR WINDOW DRIVER (DOWN) 2 Q412 14OR/LB RIGHT REAR WINDOW DRIVER (UP) 3 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP) 4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP) 5 Q11 14OR/LG LEFT FRONT WINDOW DRIVER (UP) 6 Q26 12OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN) 7 G161 20VT/DG DRIVER DOOR LOCK SWITCH MUX 8 Z939 12BK GROUND 9 F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 10 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN) 11 Z939 18BK GROUND 12 Q21 14OR/WT LEFT FRONT WINDOW DRIVER (DOWN) Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2276 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Pin Circuit Description 1 P71 20TN/DG LEFT MIRROR UP DRIVER 2 P195 18LG/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 3 A940 18RD FUSED B(+) 4 P74 18TN/OR RIGHT MIRROR LEFT DRIVER 5 Z939 18BK GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Switch-Power Sliding Backlite > Page 2277 6 P75 20TN/LG LEFT MIRROR LEFT DRIVER 7 P72 18TN/GY RIGHT MIRROR UP DRIVER 8 Q15 12OR/LB WINDOW LOCK OUT SWITCH OUTPUT Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite Power Window Switch: Diagrams Switch-Power Sliding Backlite Component ID: 499 Component : SWITCH-POWER SLIDING BACKLITE Connector: Name : SWITCH-POWER SLIDING BACKLITE Color : BLACK # of pins : 8 Qualifier : (QUAD CAB/EXCEPT BASE) Pin Circuit Description 1-2 Z974 12BK GROUND 3 Z975 12BK GROUND 4 F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 5 Q950 12OR/LG POWER BACKLITE OPEN (+) 6 P301 20LG/OR PANEL LAMPS DRIVER 7 Z976 20BK GROUND 8 Q951 12OR/VT POWER BACKLITE OPEN (-) Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2280 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2281 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2282 Power Window Switch: Diagrams Switch-Power Window-Left Rear Component ID: 500 Component : SWITCH-POWER WINDOW-LEFT REAR Connector: Name : SWITCH-POWER WINDOW-LEFT REAR Color : BLUE # of pins : 6 Pin Circuit Description 1 Q111 14TN/YL DRIVER REAR WINDOW DRIVER (UP) Pin Circuit Description 1 Q211 14TN/LB DRIVER REAR WINDOW DRIVER (DOWN) 2 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN) 3-4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP) 5 Q211 14TN/LB DRIVER REAR WINDOW DRIVER (DOWN) 5 Q111 14TN/YL DRIVER REAR WINDOW DRIVER (UP) 6 Q15 14OR/LB POWER WINDOW SWITCH FEED Component Location - 57 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2283 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2284 Power Window Switch: Diagrams Switch-Power Window-Passenger Component ID: 501 Component : SWITCH-POWER WINDOW-PASSENGER Connector: Name : SWITCH-POWER WINDOW-PASSENGER Color : BLUE # of pins : 6 Pin Circuit Description 1 Q12 12OR/BR RIGHT FRONT WINDOW DRIVER (UP) 2 Q26 12OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN) 3-4 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP) 5 Q22 12OR/VT RIGHT FRONT WINDOW DRIVER (DOWN) 6 Q15 12OR/LB POWER WINDOW SWITCH FEED Component Location - 56 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2285 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2286 Power Window Switch: Diagrams Switch-Power Window-Right Rear Component ID: 502 Component : SWITCH-POWER WINDOW-RIGHT REAR Connector: Name : SWITCH-POWER WINDOW-RIGHT REAR Color : BLUE # of pins : 6 Pin Circuit Description 1 Q112 14TN/YL PASSENGER REAR WINDOW DRIVER (UP) Pin Circuit Description 1 Q212 14TN/LB PASSENGER REAR WINDOW DRIVER (DOWN) 2 Q612 14OR/GY RIGHT REAR WINDOW DRIVER (DOWN) 3-4 Q412 14OR/WT RIGHT REAR WINDOW DRIVER (UP) 5 Q212 14TN/LB PASSENGER REAR WINDOW DRIVER (DOWN) 5 Q112 14TN/YL PASSENGER REAR WINDOW DRIVER (UP) 6 Q15 14TN/LG POWER WINDOW SWITCH FEED Component Location - 57 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2287 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2288 Power Window Switch: Diagrams Switch-Window/Door Lock-Driver Component ID 479 Component ID: 479 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Circuit Description 1 Q612 14OR/DB RIGHT REAR WINDOW DRIVER (DOWN) 2 Q412 14OR/LB RIGHT REAR WINDOW DRIVER (UP) 3 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP) 4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP) 5 Q11 14OR/LG LEFT FRONT WINDOW DRIVER (UP) 6 Q26 12OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN) 7 G161 20VT/DG DRIVER DOOR LOCK SWITCH MUX 8 Z939 12BK GROUND 9 F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 10 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN) 11 Z939 18BK GROUND 12 Q21 14OR/WT LEFT FRONT WINDOW DRIVER (DOWN) Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2289 Pin Circuit Description 1 P71 20TN/DG LEFT MIRROR UP DRIVER 2 P195 18LG/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 3 A940 18RD FUSED B(+) 4 P74 18TN/OR RIGHT MIRROR LEFT DRIVER 5 Z939 18BK GROUND 6 P75 20TN/LG LEFT MIRROR LEFT DRIVER 7 P72 18TN/GY RIGHT MIRROR UP DRIVER 8 Q15 12OR/LB WINDOW LOCK OUT SWITCH OUTPUT Component ID 518 Component ID: 518 Component : SWITCH-WINDOW/DOOR LOCK-DRIVER Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C1 Color : BLUE # of pins : 12 Pin Circuit Description 1 Q612 14OR/DB RIGHT REAR WINDOW DRIVER (DOWN) 2 Q412 14OR/LB RIGHT REAR WINDOW DRIVER (UP) 3 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP) 4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP) 5 Q11 14OR/LG LEFT FRONT WINDOW DRIVER (UP) 6 Q26 12OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2290 7 G161 20VT/DG DRIVER DOOR LOCK SWITCH MUX 8 Z939 12BK GROUND 9 F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 10 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN) 11 Z939 18BK GROUND 12 Q21 14OR/WT LEFT FRONT WINDOW DRIVER (DOWN) Component Location - 55 Connector: Name : SWITCH-WINDOW/DOOR LOCK-DRIVER C2 Color : BLUE # of pins : 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2291 Pin Circuit Description 1 P71 20TN/DG LEFT MIRROR UP DRIVER 2 P195 18LG/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) 3 A940 18RD FUSED B(+) 4 P74 18TN/OR RIGHT MIRROR LEFT DRIVER 5 Z939 18BK GROUND 6 P75 20TN/LG LEFT MIRROR LEFT DRIVER 7 P72 18TN/GY RIGHT MIRROR UP DRIVER 8 Q15 12OR/LB WINDOW LOCK OUT SWITCH OUTPUT Component Location - 55 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Switch-Power Sliding Backlite > Page 2292 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 2293 Power Window Switch: Testing and Inspection WINDOW SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in both the power window and lock switch units and the power windows are inoperative. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse in the Totally Integrated Power Module (TIPM) and the circuit breaker located near the park brake pedal. If OK, go to STEP 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Totally Integrated Power Module (TIPM). If OK, turn the ignition switch to the Off position and go to STEP 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch See: Sensors and Switches - Body and Frame/Power Door Lock Switch/Testing and Inspection/Diagnosis and Testing for service procedures. Unplug the wire harness connector from the switch unit. 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures . If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal Power Window Switch: Service and Repair Removal REMOVAL FRONT PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal 3. Remove the switch from the trim panel bezel. REAR PASSENGER 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal 3. Gently pry switch from door trim panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Removal > Page 2296 Power Window Switch: Service and Repair Installation INSTALLATION FRONT PASSENGER 1. Insert switch to trim panel bezel. 2. Install door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation 3. Connect battery negative cable. REAR PASSENGER 1. Install switch to door trim panel 2. Install door trim panel. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation 3. Connect battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Component ID: 516 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Circuit Description 1 G932 20VT/TN WASHER FLUID SWITCH RETURN 2 W1 20BR/TN WASHER FLUID SWITCH SENSE Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2301 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2302 Washer Fluid Level Switch: Diagrams Component ID: 516 Component : SWITCH-WASHER FLUID LEVEL Connector: Name : SWITCH-WASHER FLUID LEVEL Color : LT. GRAY # of pins : 2 Pin Circuit Description 1 G932 20VT/TN WASHER FLUID SWITCH RETURN 2 W1 20BR/TN WASHER FLUID SWITCH SENSE Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 2303 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description Washer Fluid Level Switch: Description and Operation Description DESCRIPTION The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir adjacent to the washer pump/motor unit in the engine compartment. Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Description > Page 2306 Washer Fluid Level Switch: Description and Operation Operation OPERATION The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (gasoline engines) or left (diesel engines) headlamp and dash wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch and the hard wired circuits between the switch and the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level switch or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer systems. The most reliable, efficient, and accurate means to diagnose the washer fluid level switch or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal Washer Fluid Level Switch: Service and Repair Removal Diesel Engine DIESEL ENGINE NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose (4) from the barbed outlet nipple of the washer pump/motor unit (3) and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the left headlamp and dash wire harness (1) connector for the washer fluid level switch (5) from the switch connector receptacle. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 5. Remove the switch from the reservoir. 6. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. Gasoline Engine GASOLINE ENGINE NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose (1) from the barbed outlet nipple of the washer pump/motor unit (5) and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the right headlamp and dash wire harness (4) connector for the washer fluid level switch (3) from the switch connector receptacle. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal > Page 2309 5. Remove the switch from the reservoir. 6. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Removal > Page 2310 Washer Fluid Level Switch: Service and Repair Installation Diesel Engine DIESEL ENGINE 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch (5) through the rubber grommet seal and in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be pointed upward. 4. Reconnect the left headlamp and dash wire harness (1) connector for the switch to the switch connector receptacle. 5. Reconnect the removed washer hose (4) to the barbed outlet nipple of the washer pump/motor unit (3). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Gasoline Engine GASOLINE ENGINE 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2). Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch (3) through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be pointed upward. 4. Reconnect the right headlamp and dash wire harness (4) connector to the switch connector receptacle. 5. Reconnect the removed washer hose (1) to the barbed outlet nipple of the washer pump/motor unit (5). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) Alignment: Specifications Curb Height Measurement (LD) CURB HEIGHT MEASUREMENT (LD) The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Front - On each side of the vehicle, measure the distance from the center of the rear lower control arm bolt (1) to the ground (2) Record the measurement. Next measure the distance from the spindle center (3) to the ground (4) Record the measurement. 2. Take the two measurements and subtract them to get the curb height specification. 3. Rear 4X2 LD - On each side of the vehicle, measure the distance at the axle tube (1) to the jounce bumper flange (2). 4. Rear 4X4 LD - On each side of the vehicle, measure the distance at the jounce pad welded to the axle tube (1) to the jounce bumper flange (2). 5. Compare the measurements to the specifications listed in the following Curb Height Specifications chart. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2316 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2317 Alignment: Specifications Curb Height Measurement (HD) CURB HEIGHT MEASUREMENT (HD) The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Front 4X2 On each side of the vehicle, measure the distance from the top of the jounce bumper flange (2) to the bottom of the frame rail (1). 2. Front 4X4 On each side of the vehicle, measure the distance from the top of the axle (2) to the bottom of the jounce bumper flange (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2318 3. Rear ALL - On each side of the vehicle, measure the distance at the top of the axle tube (2) to the bottom of the frame rail (1). 4. Compare the measurements to the specifications listed in the following Curb Height Specifications chart. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2319 Alignment: Specifications Wheel Alignment Specifications Ram 1500 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2320 Ram 2500 SERIES - 4X2 Ram 2500 SERIES - 4X4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2321 Ram 2500 SERIES MEGA CAB 4X4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2322 Ram 3500 SERIES 4X2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2323 Ram 3500 SERIES 4X4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2324 Ram 3500 SERIES CAB CHASSIS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2325 Ram 4500 SERIES Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Curb Height Measurement (LD) > Page 2326 Ram 5500 SERIES Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Description Alignment: Description and Operation Description DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Description > Page 2329 Alignment: Description and Operation Operation OPERATION - CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns - CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire - TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment - THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 2330 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. Road test the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm (2) in conjunction with the slotted holes in the frame brackets (1). Vehicle should be at normal ride height. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2333 Alignment: Service and Repair Alignment - Rack and Pinion Steering System ALIGNMENT - RACK AND PINION STEERING SYSTEM CAMBER, CASTER AND TOE ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets (1). CASTER Moving the front or rear position of the lower control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the lower control arm in or out. Then move the other pivot bolt of the lower control arm in the opposite direction. To increase positive caster angle, move the rear position of the lower control arm inward (toward the engine). Move the front of the lower control arm outward (away from the engine) slightly until the desired camber angle is obtained. CAMBER Move both pivot bolts of the lower control arm together in or out. This will change the camber angle significantly and little effect on the caster angle. After adjustment is made tighten the lower control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2334 NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). NOTE: Make sure the toe setting does not change during tightening. 5. Verify the specifications 6. Turn off engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2335 Alignment: Service and Repair Alignment - Recirculating Ball Steering System ALIGNMENT - RECIRCULATING BALL STEERING SYSTEM NOTE: For 4500/5500 only, if an alignment is being performed WITHOUT having replaced the LH tie rod end, the Tie Rod Ball Stud Housing Misalignment Check 4500/5500 procedure must be preformed as the first step. The Tie Rod Ball Stud Housing Misalignment Check 4500/5500 procedure will determine if the LH tie rod end needs to be serviced due to excessive internal stress during turns. 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 adjustment: 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 turns. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability. For 2500/3500, caster can be adjusted by rotating the cams (3) on the lower suspension arm. For 4500/5500, caster can be adjusted by loosening the bolts on the lower suspension arm, moving the arm within the slot and tightening the bolt. TOE POSITION: The wheel toe position adjustment should be the final adjustment. 1. For 4500/5500 only, if an alignment is being performed without having replaced the LH tie rod end, the Tie Rod Ball Stud Housing Misalignment Check 4500/5500 procedure must be performed prior to loosening any adjustment sleeve. If the LH tie rod end has just been replaced, proceed with step 2. 2. Start the engine and turn wheels both ways before straightening the wheels. Center and secure the steering wheel and turn off engine. 3. Loosen the adjustment sleeve clamp bolts. NOTE: With the vehicle in a level position, verify the drag link/tie rod ball joints are not twisted and are centered. Rotate drag link/tie rod until ball joints are level. 4. Adjust the right wheel toe position with the drag link adjuster sleeve. Turn the sleeve until the right wheel is at the correct specification. Verify a level drag link ball joint. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 5. Adjust the left wheel toe position with the tie rod adjuster sleeve. Turn the sleeve until the left wheel is at the correct specification. Verify a level tie rod ball joint. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. CAUTION: For 4500/5500, setting the toe can put the tie rod ball stud alignment out of specifications causing damage to the LH tie rod. The procedure must be run again to verify or reset. 6. For 4500/5500 only, perform the Tie Rod Ball Stud Housing Misalignment Check 4500/5500 to verify it is still within specifications. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2336 NOTE: After setting toe to specifications, normalization of the tie rod to knuckle must be verified to be sure that the adjustments are correct. 7. For 2500/3500, to normalize, venfy the lower surface of the outer tie rod socket (2) is parallel to the upper surface ofthe knuckle (1). Rotate the drag link/tie rod until ball joint to knuckle is parallel. NOTE: Toe setting may change during tightening, Make sure to verify reading after tightening. 8. Verify the steering wheel is straight and the toe settings are correct (repeat steps 2-6 if necessary). 9. Road test the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2337 Alignment: Service and Repair Toe Adjustment - Rack and Pinion Steering System TOE ADJUSTMENT - RACK AND PINION STEERING SYSTEM 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. NOTE: Make sure the toe setting does not change during tightening. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). 5. Verify the specifications. 6. Road test the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2338 Alignment: Service and Repair Camber and Caster Adjustment CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm (2) in conjunction with the slotted holes in the frame brackets (1). Vehicle should be at normal ride height. Alignment - Rack and Pinion Steering System ALIGNMENT - RACK AND PINION STEERING SYSTEM CAMBER, CASTER AND TOE ADJUSTMENT Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets (1). CASTER Moving the front or rear position of the lower control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the lower control arm in or out. Then move the other pivot bolt of the lower control arm in the opposite direction. To increase positive caster angle, move the rear position of the lower control arm inward (toward the engine). Move the front of the lower control arm outward (away from the engine) slightly until the desired camber angle is obtained. CAMBER Move both pivot bolts of the lower control arm together in or out. This will change the camber angle significantly and little effect on the caster angle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2339 After adjustment is made tighten the lower control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). NOTE: Make sure the toe setting does not change during tightening. 5. Verify the specifications 6. Turn off engine. Alignment - Recirculating Ball Steering System ALIGNMENT - RECIRCULATING BALL STEERING SYSTEM NOTE: For 4500/5500 only, if an alignment is being performed WITHOUT having replaced the LH tie rod end, the Tie Rod Ball Stud Housing Misalignment Check 4500/5500 procedure must be preformed as the first step. The Tie Rod Ball Stud Housing Misalignment Check 4500/5500 procedure will determine if the LH tie rod end needs to be serviced due to excessive internal stress during turns. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2340 CAMBER: The wheel camber angle is preset and is not adjustable. CASTER adjustment: 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 turns. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability. For 2500/3500, caster can be adjusted by rotating the cams (3) on the lower suspension arm. For 4500/5500, caster can be adjusted by loosening the bolts on the lower suspension arm, moving the arm within the slot and tightening the bolt. TOE POSITION: The wheel toe position adjustment should be the final adjustment. 1. For 4500/5500 only, if an alignment is being performed without having replaced the LH tie rod end, the Tie Rod Ball Stud Housing Misalignment Check 4500/5500 procedure must be performed prior to loosening any adjustment sleeve. If the LH tie rod end has just been replaced, proceed with step 2. 2. Start the engine and turn wheels both ways before straightening the wheels. Center and secure the steering wheel and turn off engine. 3. Loosen the adjustment sleeve clamp bolts. NOTE: With the vehicle in a level position, verify the drag link/tie rod ball joints are not twisted and are centered. Rotate drag link/tie rod until ball joints are level. 4. Adjust the right wheel toe position with the drag link adjuster sleeve. Turn the sleeve until the right wheel is at the correct specification. Verify a level drag link ball joint. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 5. Adjust the left wheel toe position with the tie rod adjuster sleeve. Turn the sleeve until the left wheel is at the correct specification. Verify a level tie rod ball joint. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. CAUTION: For 4500/5500, setting the toe can put the tie rod ball stud alignment out of specifications causing damage to the LH tie rod. The procedure must be run again to verify or reset. 6. For 4500/5500 only, perform the Tie Rod Ball Stud Housing Misalignment Check 4500/5500 to verify it is still within specifications. NOTE: After setting toe to specifications, normalization of the tie rod to knuckle must be verified to be sure that the adjustments are correct. 7. For 2500/3500, to normalize, venfy the lower surface of the outer tie rod socket (2) is parallel to the upper surface ofthe knuckle (1). Rotate the drag link/tie rod until ball joint to knuckle is parallel. NOTE: Toe setting may change during tightening, Make sure to verify reading after tightening. 8. Verify the steering wheel is straight and the toe settings are correct (repeat steps 2-6 if necessary). 9. Road test the vehicle. Toe Adjustment - Rack and Pinion Steering System TOE ADJUSTMENT - RACK AND PINION STEERING SYSTEM Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2341 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (1). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. NOTE: Make sure the toe setting does not change during tightening. 4. Tighten the tie rod jam nut (1) to 127 Nm (94 ft. lbs.). 5. Verify the specifications. 6. Road test the vehicle. Toe Adjustment - Recirculating Ball Steering System TOE ADJUSTMENT - RECIRCULATING BALL STEERING SYSTEM NOTE: For 4500/5500 only, if an alignment is being performed WITHOUT having replaced the LH tie rod end, the Tie Rod Ball Stud Housing Misalignment Check 4500/5500 procedure must be preformed as the first step. The Tie Rod Ball Stud Housing Misalignment Check 4500/5500 procedure will determine if the LH tie rod end needs to be serviced due to excessive internal stress during turns. The wheel toe position adjustment is the final adjustment. 1. For 4500/5500 only, if an alignment is being performed without having replaced the LH tie rod end, the Tie Rod Ball Stud Housing Misalignment Check 4500/5500 procedure must be performed prior to loosening any adjustment sleeve If the LH tie rod end has just been replaced, proceed with step 2. 2. Start the engine and turn wheels both ways before straightening the wheels. Center and secure the steering wheel and turn off engine. 3. Loosen the adjustment sleeve clamp bolts. NOTE: With the vehicle in a level position, verify the drag link/tie rod ball joints are not twisted and are centered. Rotate drag link/tie rod until ball joints are level. 4. Adjust the right wheel toe position with the drag link adjuster sleeve. Turn the sleeve until the right wheel is at the correct specification. Verify a level drag link ball joint. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 5. Adjust the left wheel toe position with the tie rod adjuster sleeve. Turn the sleeve until the left wheel is at the correct specification. Verify a level tie rod ball joint. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. CAUTION: For 4500/5500, setting the toe can put the tie rod ball stud alignment out of specifications causing damage to the LH tie rod. The procedure must be run again to verify or reset. 6. For 4500/5500 only, perform the Tie Rod Ball Stud Housing Misalignment Check 4500/5500 to verify it is still within specifications. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2342 NOTE: After setting toe to specifications, normalization of the tie rod to knuckle must be verified to be sure that the adjustments are correct. 7. For 2500/5500, to normalize, verify the lower surface of the outer tie rod socket (2) is parallel to the upper surface ofthe knuckle (1). Rotate the drag link/tie rod until ball joint to knuckle is parallel. NOTE: Toe setting may change during tightening, Make sure to verify reading after tightening. 8. Verify the steering wheel is straight and the toe settings are correct (repeat steps 2-6 if necessary). 9. Road test the vehicle. Curb Height Measurement (LD) CURB HEIGHT MEASUREMENT (LD) The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Front - On each side of the vehicle, measure the distance from the center of the rear lower control arm bolt (1) to the ground (2) Record the measurement. Next measure the distance from the spindle center (3) to the ground (4) Record the measurement. 2. Take the two measurements and subtract them to get the curb height specification. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2343 3. Rear 4X2 LD - On each side of the vehicle, measure the distance at the axle tube (1) to the jounce bumper flange (2). 4. Rear 4X4 LD - On each side of the vehicle, measure the distance at the jounce pad welded to the axle tube (1) to the jounce bumper flange (2). 5. Compare the measurements to the specifications listed in the following Curb Height Specifications chart. Curb Height Measurement (HD) CURB HEIGHT MEASUREMENT (HD) The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. 1. Front 4X2 On each side of the vehicle, measure the distance from the top of the jounce bumper flange (2) to the bottom of the frame rail (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2344 2. Front 4X4 On each side of the vehicle, measure the distance from the top of the axle (2) to the bottom of the jounce bumper flange (1). 3. Rear ALL - On each side of the vehicle, measure the distance at the top of the axle tube (2) to the bottom of the frame rail (1). 4. Compare the measurements to the specifications listed in the following Curb Height Specifications chart. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2345 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder. Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 2352 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than +/- 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 2353 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed Information Not Supplied by the Manufacturer Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL There is no longer a Filter Minder on the MY08 Diesel Engines. There will be an EVIC message which will display when the filter restriction reaches it's maximum. The customer will be required to replace it with-in 250 miles (402 KM) Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2362 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2367 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2368 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description > Page 2371 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel Filter/Water Separator Removal/Installation. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules, for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2374 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2375 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2376 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. Refer to Standard Procedures-Fuel System Priming. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2377 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 2378 a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread O-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. The cylinders are numbered front to rear ; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Specifications Compression Ratio .............................................................................................................................. ....................................................................... 17.2 : 1 Compression Pressure (Minimum) ...................................................................................................... ....................................................................... 350 psi Max Variation Between Cylinders ........................................................................................................ ............................................................ Not available Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60° C (140° F). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Removal . 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjustment/resettingis not necessary. If measurement finds the lash outside of the limits, adjustment/resettingis required. 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > Page 2388 7. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits. 8. Install the cylinder head cover See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Installation . 9. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams With A/C 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- A/C Compressor Pulley 7- Accessory Drive Belt Tensioner 8- Generator 9Water Pump Pulley Without A/C Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2392 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- Accessory Drive Belt Tensioner 7- Generator 8- Water Pump Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2393 Drive Belt: Description and Operation DESCRIPTION The accessory drive belt is a serpentine type belt. Satisfactory performance of these belts depends on belt condition and proper belt tension. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2394 Drive Belt: Testing and Inspection DIAGNOSIS AND TESTING VISUAL DIAGNOSIS NOTE: Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor ( located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib , are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2395 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 2396 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 2399 Drive Belt: Removal and Replacement Accessory Drive Belt - Removal 6.7L DIESEL Belt Routing-Diesel Engine Without A/C 1. A 1/2 inch square hole is provided in the automatic belt tensioner. Attach a suitable tool into this hole. BELT ROUTING-DIESEL WITH A/C 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from water pump pulley first. 4. Remove belt from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 2400 Accessory Drive Belt - Installation 6.7L DIESEL Belt Routing - DIESEL WITH A/C CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. 1. Position drive belt over all pulleys except water pump pulley. 2. Attach a suitable tool to the accessory drive belt tensioner. Belt Routing - DIESEL WITHOUT A/C 3. Rotate accessory drive belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove tool. Be sure belt Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 2401 is properly seated on all pulleys. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL There is no longer a Filter Minder on the MY08 Diesel Engines. There will be an EVIC message which will display when the filter restriction reaches it's maximum. The customer will be required to replace it with-in 250 miles (402 KM) Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2408 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Chrysler provides no information on a Cabin Air Filter for this vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation DESCRIPTION The Closed Crankcase Ventilation System (CCV) consists of several parts to make it functional. One part is the filter. The filter is serviceable and prevents oil mist from entering the discharge tube of the CCV system. It is not cleaned, but replaced at 60,000 mile intervals. The crankcase breather assembly is integrated into the cylinder head cover (3) and is serviced separately. The external fittings (2) to the breather tube and breather drain tube are serviceable. The crankcase breather assembly is integrated into the cylinder head cover and corresponding breather cover. Crankcase gasses travel into the breather cavity under the breather cover where they pass through a filtering media (serviceable maintenance component) which separates the oil from the crankcase gasses. The oil drains back into the engine block through two hoses (2) on the left side of the engine. The crankcase gasses are directed through the Crankcase Depression Regulator (CDR) valve which allows the system to maintain a constant positive pressure in the crankcase. The CDR valve is a non-serviceable component located on the underside of the breather cover. Clean crankcase gasses flow from the CDR valve into the fresh air side of the turbocharger compressor. The closed crankcase ventilation valve is used to vent the crankcase gases back into the intake of engine. If the crankcase ventilation filter becomes too restrictive, under high intake vacuum situations, the closed crankcase ventilation prevents the engine from syphoning crankcase gases/oil from the crankcase of the engine. The closed crankcase ventilation valve is located under the crankcase ventilation filter cover at the top of the engine. TESTING 1. If troubleshooting high crankcase pressure, the following items can be causing the closed crankcase ventilation valve to close during engine Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and Operation > Page 2415 operation: High air intake restriction. Check for high intake restriction - A restricted crankcase ventilation filter. Change the filter - A malfunctioning or misassembled closed crankcase ventilation valve. Check the valve operation and change if necessary 2. The closed crankcase ventilation valve should allow crankcases gases to flow when the engine is not running and/or removed from the engine. NOTE: Application of air can be applied either to the inlet or outlet of the closed crankcase ventilation valve. 3. A small amount of air can be blown through the closed crankcase ventilation valve (less than 34 kPa [5 psi]) to check the closed crankcase ventilation valve. 4. If air does not go through the closed crankcase ventilation valve, replace the valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Service and Repair > Procedures Crankcase Filter: Procedures FILTER ELEMENT INSPECTION 1. Inspect the crankcase breather assembly by ensuring the oil drain hoses are not kinked or cracked. 2. Inspect all external hose connections for signs of leakage, repair where necessary. Inspect the breather for cracks or damage. 3. Inspect the filter element sealing surface for gouges or cracks; this surface should be smooth and free of abrasions. FILTER ELEMENT INSTALLATION 1. Clean the filter sealing surface on the cylinder head cover with a clean shop towel. 2. Install the new filter element, lubrication of the new sealing surface is not recommended. 3. Press the new filter into the cylinder head cover cavity until fully seated. 4. Install the breather cover assembly. BREATHER COVER INSTALLATION 1. Inspect the filter element for proper installation. The filter should be completely seated around the circumference of the sealing surface. 2. Install the breather cover to the cylinder head cover. 3. Install the capscrews surrounding the breather cover. 4. Install the breather drain hoses onto the hose barbs. Do not damage or hose connection during installation. 5. Install engine shields or covers if equipped. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Service and Repair > Procedures > Page 2418 Crankcase Filter: Removal and Replacement REMOVAL 1. Remove any engine heat shields or EGR shields if equipped. 2. Using hose clamp pliers, loosen the breather plumbing from the breather cover connections. 3. Carefully remove the breather hoses (2) from the breather cover assembly (3). 4. Remove the capscrews surrounding the parameter of the breather cover (3). 5. Separate the breather cover (3) assembly from the cylinder head cover (1). FILTER ELEMENT REMOVAL 1. With the breather cover removed, remove the filter element from the cylinder head cover cavity by lifting the element straight up from its sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid Filter - A/T: Service and Repair 68RFE Automatic Transmission FLUID AND FILTER REPLACEMENT For proper service intervals See: . REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the appropriate diagnostic procedure. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2423 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2424 Fluid Filter - A/T: Service and Repair 48RE Automatic Transmission FLUID AND FILTER REPLACEMENT For proper service intervals See: . The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2425 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/48RE (A-618) 4 Speed/Transmission Fill - 48RE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2426 Fluid Filter - A/T: Service and Repair AS68RC Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and o-ring seal from the valve body (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2427 INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the appropriate diagnostic procedure. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION TRANSMISSION OIL FILTER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2428 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/AS68RC Automatic Transmission/Transmission Fill - AS68RC Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2433 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 2434 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Description and Operation > Description > Page 2437 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel Filter/Water Separator Removal/Installation. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules, for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2440 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2441 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2442 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. Refer to Standard Procedures-Fuel System Priming. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2443 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Removal > Page 2444 a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Removal Oil Filter: Service and Repair Removal REMOVAL 1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter wrench. 2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure it is removed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Removal > Page 2449 Oil Filter: Service and Repair Installation INSTALLATION 1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine. 2. Apply a light film of lubricating oil to the sealing surface before installing the filter. CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal. 3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional 1/2 turn. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Discharge Line Hose/Line HVAC: Description and Operation Discharge Line DESCRIPTION The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser and has an integral fitting for the A/C pressure transducer See: Heating and Air Conditioning/Refrigerant Pressure Sensor / Switch/Description and Operation/Description . The A/C discharge line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose See: Heating and Air Conditioning/Description and Operation/Plumbing/Description . The A/C discharge line for the 5.9L and 6.7L diesel engines is serviced as an assembly with the A/C suction line. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is removed. The A/C discharge line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Discharge Line > Page 2455 Hose/Line HVAC: Description and Operation Liquid Line DESCRIPTION The A/C liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line consists of two separate lines that connect to each other using a spring-lock type refrigerant line coupler See: Heating and Air Conditioning/Coupler HVAC/Description and Operation/Description . The A/C liquid line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose. NOTE: A/C orifice tube size is different between gasoline and diesel engines. Be sure to use the correct A/C liquid line when replacement of the A/C orifice tube is required. The front section of the A/C liquid line includes the high-side service port and the rear section of the A/C liquid line includes the A/C fixed orifice tube. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid line has no serviceable parts except for the O-ring seals and gaskets, high-side service port valve, cap and secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid line is removed. The A/C liquid line cannot be repaired and must be replaced if found to be leaking or damaged, or if the fixed orifice tube is inoperative. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Discharge Line > Page 2456 Hose/Line HVAC: Description and Operation Suction Line DESCRIPTION The A/C suction line is the refrigerant line that goes from the A/C evaporator to the A/C compressor. The A/C suction line is made from light-weight aluminum tubing with braze-less and crimp type fittings and nylon tubes with rubber barrier hose See: Heating and Air Conditioning/Description and Operation/Plumbing/Description . The A/C suction line for the 5.9L and 6.7L diesel engines is serviced as an assembly with the A/C discharge line. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C suction line has no serviceable parts except for the O-ring seals and the secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is removed. The A/C suction line cannot be repaired and must be replaced if found to be leaking or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line - Removal Hose/Line HVAC: Service and Repair A/C Line - Removal Discharge Line 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C discharge line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C suction line. 1. Disconnect and isolate the negative battery cables. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery . 3. Remove the air filter housing cover. 4. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 5. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Removal . 6. Install plugs in, or tape over the opened suction line fitting and the accumulator tube. 7. Disconnect the wire harness connector (5) from the A/C pressure transducer (4). 8. Remove the nut (2) that secures the A/C suction and discharge line assembly (3) to the A/C condenser (1). 9. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 10. Remove the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor (6). 11. Disconnect the A/C suction and discharge line assembly from the A/C compressor and remove and discard the O-ring seals and gasket. 12. Remove the A/C suction and discharge line assembly from the engine compartment. 13. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and compressor ports. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line See: Heating and Air Conditioning/Refrigerant Pressure Sensor / Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line - Removal > Page 2459 Switch/Service and Repair/Removal . Liquid Line 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution. Failure to follow the warnings and cautions could result in possible personal injury or death. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery . 3. Remove the passenger side battery See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal . 4. Remove the air seal from the right end of the A/C condenser (5) to gain access to the refrigerant line fittings. 5. Remove the nut (2) that secures the front section of the A/C liquid line (1) to the A/C condenser (3). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring and gasket. 7. Disengage the A/C liquid line (1) from the three body retaining clips (2 and 3) located at the right front corner of the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line - Removal > Page 2460 8. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line (1) to the rear section of the liquid line (3). 9. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Removal . 10. Install plugs in, or tape over the opened ends of the A/C liquid lines and the condenser port. 11. Remove the front section of the A/C liquid line from the engine compartment. REAR SECTION 12. Disconnect and isolate the negative battery cable. 13. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery . 14. Remove the passenger side battery See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal . 15. Disengage the rear section of the A/C liquid line (2) from the body retaining clip (5). 16. Remove the secondary retaining clip (1) from the spring-lock coupler that secures the front section of the A/C liquid line (6) to the rear section of the A/C liquid line. 17. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Removal . 18. Remove the secondary retaining clip (3) from the spring-lock coupler that secures the rear section of the A/C liquid line to the evaporator tube (4). 19. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C liquid line from the evaporator tube and remove and discard the O-ring seals See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Removal . 20. Install plugs in, or tape over the opened ends of the A/C liquid lines and the evaporator tube, 21. Remove the rear section of the A/C liquid line from the engine compartment. Suction Line 5.9L/6.7L DIESEL ENGINES WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution. Failure to follow the warnings and cautions could result in possible personal injury or death. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line - Removal > Page 2461 NOTE: The A/C suction line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C discharge line. 1. Disconnect and isolate the negative battery cables. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery . 3. Remove the air filter housing cover. 4. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 5. Using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Removal . 6. Install plugs in, or tape over the opened suction line fitting and the accumulator tube. 7. Disconnect the wire harness connector (5) from the A/C pressure transducer (4). 8. Remove the nut (2) that secures the A/C suction and discharge line assembly (3) to the A/C condenser (1). 9. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 10. Remove the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor (6). 11. Disconnect the A/C suction and discharge line assembly from the A/C compressor and remove and discard the O-ring seals and gasket. 12. Remove the A/C suction and discharge line assembly from the engine compartment. 13. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and compressor ports. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line See: Heating and Air Conditioning/Refrigerant Pressure Sensor / Switch/Service and Repair/Removal . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line - Removal > Page 2462 Hose/Line HVAC: Service and Repair A/C Line - Installation Discharge Line 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C discharge line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C suction line. 1. If removed, install the A/C pressure transducer (4) onto the A/C suction and discharge line assembly (3) See: Heating and Air Conditioning/Refrigerant Pressure Sensor / Switch/Service and Repair/Installation . 2. Remove the tape or plugs from the opened refrigerant line fittings and the condenser and compressor ports. 3. Position the A/C suction and discharge line assembly into the engine compartment. 4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the A/C suction and discharge line assembly to the A/C condenser (1). 6. Install the nut (2) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 23 Nm (17 ft. lbs.). 7. Connect the A/C suction and discharge line assembly to the A/C compressor (6). 8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.). 9. Connect the wire harness connector (5) to the A/C pressure transducer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line - Removal > Page 2463 10. Remove the tape or plugs from the opened accumulator tube. 11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C suction line (6) to the spring-lock coupler (1) on the A/C accumulator (5) and install the secondary retaining clip (7) See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Installation . 13. Install the air filter housing cover. 14. Reconnect the negative battery cables. 15. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate . 16. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . 17. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge . Liquid Line 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION 1. Position the front section of the A/C liquid line (1) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the condenser port. 3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line - Removal > Page 2464 O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C liquid line to the rear section of the liquid line (3) See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Installation . 5. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line onto the rear section of the liquid line. 6. Engage the A/C liquid line (1) into the three body retaining clips (2 and 3) located at the right front corner of the engine compartment. 7. Lubricate a new O-ring with clean refrigerant oil and install it and a new gasket onto the front liquid line fitting. Use only the specified O-ring seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line (2) to the condenser port. 9. Install the nut (1) that secures the A/C liquid line to the A/C condenser (3). Tighten the nut to 23 Nm (17 ft. lbs.). 10. Position the air seal over the right end of the A/C condenser and install the air seal retainers. 11. Install the passenger side battery tray See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray - Installation . 12. Reconnect the negative battery cable(s). 13. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate . 14. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . 15. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge . REAR SECTION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line - Removal > Page 2465 16. Position the rear section of the A/C liquid line (2) into the engine compartment. 17. Remove the tape or plugs from the opened ends of the A/C liquid lines and the evaporator tube (4). 18. Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear liquid line spring-lock coupler fitting. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 19. Connect the rear section of the A/C liquid line to the evaporator tube See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Installation . 20. Install the secondary retaining clip (3) onto the spring-lock coupler that secures the rear section of the A/C liquid line onto the evaporator tube. 21. Engage the A/C liquid line into the body retaining clip (5). 22. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 23. Connect the rear section of the A/C liquid line (6) to the front section of the liquid line See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Installation . 24. Install the secondary retaining clip (1) onto the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line. 25. Install the passenger side battery tray See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray - Installation . 26. Reconnect the negative battery cables. 27. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate . 28. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . 29. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge . Suction Line 5.9L/6.7L DIESEL ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C suction line for the 5.9L and the 6.7L diesel engine is serviced as an assembly with the A/C discharge line. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line - Removal > Page 2466 1. If removed, install the A/C pressure transducer (4) onto the A/C suction and discharge line assembly (3) See: Heating and Air Conditioning/Refrigerant Pressure Sensor / Switch/Service and Repair/Installation . 2. Remove the tape or plugs from the opened refrigerant line fittings and the condenser and compressor ports. 3. Position the A/C suction and discharge line assembly into the engine compartment. 4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the A/C suction and discharge line assembly to the A/C condenser (1). 6. Install the nut (2) that secures the A/C suction and discharge line assembly to the A/C condenser. Tighten the nut to 23 Nm (17 ft. lbs.). 7. Connect the A/C suction and discharge line assembly to the A/C compressor (6). 8. Install the bolt (7) that secures the A/C suction and discharge line assembly to the A/C compressor. Tighten the bolt to 23 Nm (17 ft. lbs.). 9. Connect the wire harness connector (5) to the A/C pressure transducer. 10. Remove the tape or plugs from the opened accumulator tube. 11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C suction line (6) to the spring-lock coupler (1) on the A/C accumulator (5) and install the secondary retaining clip (7) See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Installation . 13. Install the air filter housing cover. 14. Reconnect the negative battery cables. 15. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate . 16. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . 17. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses - Removal Power Steering Line/Hose: Service and Repair Power Steering Hoses - Removal I.F.S. - Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (1) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. I.F.S. - Pressure Hose PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear. 5. Remove the pressure hose from the vehicle. I.F.S. - Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. Link/Coil - Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses - Removal > Page 2471 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (2) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. Link/Coil - Pressure Hose PRESSURE HOSE 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear (4). 5. Remove the pressure hose from the vehicle. Link/Coil - Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses - Removal > Page 2472 Power Steering Line/Hose: Service and Repair Power Steering Hoses - Installation I.F.S. - Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (1) at the gear. Tighten the hose to 50 Nm (37 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair I.F.S. - Pressure Hose PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 31 Nm (23 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair I.F.S. - Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hoses - Removal > Page 2473 Link/Coil - Return Hose - Gear To Cooler RETURN HOSE - GEAR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (2) at the gear. Tighten the hose to 51 Nm (38 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair Link/Coil - Pressure Hose PRESSURE HOSE NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear (4). Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 36 Nm (27 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair Link/Coil - Return Hose - Reservoir To Cooler RETURN HOSE - RESERVOIR TO COOLER 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2479 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 2480 Brake Fluid: Specifications BRAKE FLUID Mopar DOT 3 and SAE J1703 or equivalent. NOTE: If DOT 3 is not available, then DOT 4 or DOT 4+ is acceptable. Use only recommended brake fluids. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Description and Operation > Fluid Brake Fluid: Description and Operation Fluid BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Description and Operation > Fluid > Page 2483 Brake Fluid: Description and Operation Brake Fluid BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Description and Operation > Page 2484 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Description and Operation > Page 2485 Brake Fluid: Service and Repair BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2490 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Page 2491 Clutch Fluid: Specifications Chrysler does not provide a fluid type specification for the master/slave cylinder. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2496 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity ..................................................................................................................... ........................................................ 22.6 qts (21.4L) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2499 Coolant: Fluid Type Specifications ENGINE COOLANT Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Engine Coolant Coolant: Description and Operation Engine Coolant ENGINE COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT) may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic. The increased temperature can result in sever engine damage. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Engine Coolant > Page 2502 Coolant: Description and Operation Coolant Description HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol based coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT) may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic. The increased temperature can result in severe engine damage. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Operation OPERATION Coolant flows through the engine block, cylinder head, absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. On the 6.7L diesel engine, coolant also flows through the EGR cooler and turbocharger actuator. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 2503 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or Tool 8266, refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and are not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2508 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2513 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2518 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2523 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2528 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2529 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2530 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2531 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Service Fill 42RLE .................................................................................................................................................. ............................................................. 3.8L (4.0 Qt) 45RFE/545RFE 4X2 ............................................................................................................................ .......................................................................................... 5.2 (5.5 Qt) 4X4 ........................................ .............................................................................................................................................................. .............. 6.2L (6.5 Qt) 48RE .................................................................................................................................................... ............................................................. 3.8L (4.0 Qt) 68RFE 4X2 .......................................................................................................................................... ............................................................................ 5.2 (5.5 Qt) 4X4 ...................................................... .............................................................................................................................................................. 6.2L (6.5 Qt) AS68RC ............................................................................................................................................... ............................................................. 6.8L (7.2 Qt) Overhaul * 42RLE .................................................................................................................................................. ............................................................. 8.3L (8.7 Qt) 45RFE/545RFE ................................................................................................................................... ............................................... 14-16L (14.8-16.9 Qt) 48RE .................................................................................................................................................... ............................................... 14-16L (14.8-16.9 Qt) 68RFE ................................................................................................................................................. .......................................... 15.6-16.6L (16.4-17.5 Qt) AS68RC ............................................................................................................................................... .......................................................... 13L (13.74 Qt) *Dry fill capacity. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2534 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid ............................................................................................................. .......................................................... Mopar ATF +4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Description and Operation > Description Fluid - A/T: Description and Operation Description AUTOMATIC TRANSMISSION FLUID AUTOMATIC TRANSMISSION (ALL BUT AISIN TRANSMISSION) NOTE: Refer to fluid level checking procedures. Mopar(R) ATF +4, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler automatic transmissions. Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Mopar(R) ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. AISIN TRANSMISSION Mopar(R) AS68RC, Automatic Transmission Fluid is the recommended fluid for AISIN AS68RC TRANSMISSION. Mopar(R) AS68RC, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. Mopar(R) AS68RC, also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. FLUID ADDITIVES Chrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of Chrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Description and Operation > Description > Page 2537 Fluid - A/T: Description and Operation Operation OPERATION - AUTOMATIC TRANSMISSION FLUID The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain consistent. Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission Fluid - A/T: Testing and Inspection 68RFE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 2540 Fluid - A/T: Testing and Inspection 48RE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has two primary causes. 1. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 2. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 2541 Fluid - A/T: Testing and Inspection AS68RC Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid. - failure to clean dipstick and fill tube when checking level. - engine coolant entering the fluid. - internal failure that generates debris. - overheat that generates sludge (fluid breakdown). - failure to replace contaminated converter after repair. The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid - A/T: Service and Repair 68RFE Automatic Transmission Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT For proper service intervals See: . REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the appropriate diagnostic procedure. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2544 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Fluid Level Check - 68RFE FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. FILL TUBE EQUIPPED WITH INDICATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2545 68RFE FLUID FILL CHART NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. CAPPED FILL TUBE 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336 into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2546 6. Check transmission oil temperature using the appropriate scan tool. NOTE: The true transmission oil temperature can only be read by a scan tool in REVERSE or any forward gear position. 7. The transmission Oil Dipstick 9336 has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil level is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2547 Fluid - A/T: Service and Repair 48RE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (1) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar(R) ATF +4 to restore correct level. Do not overfill. PROCEDURE TWO Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2548 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into NEUTRAL. 5. Hook up scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT For proper service intervals See: . The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2549 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2550 appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/48RE (A-618) 4 Speed/Transmission Fill - 48RE Transmission Fill - 48RE TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2551 Fluid - A/T: Service and Repair AS68RC Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the gear train churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. Optimum fluid temperature for checking the level should be between 70°C (158°F) and 80°C ( 176°F). 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Connect the scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2552 NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2553 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and o-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the appropriate diagnostic procedure. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2554 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/AS68RC Automatic Transmission/Transmission Fill - AS68RC Transmission Fill - AS68RC TRANSMISSION FILL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 2555 To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) AS68RC ATF to transmission: a. If only fluid and filter were changed, add 6.8L (7.2 quarts) of AS68RC to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 13L (13.75 quarts) of Mopar(R) AS68RC ATF to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2560 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2565 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Fluid Capacity G56 ...................................................................................................................................................... ......................................................... 5.9 L ( 12.4 Pt ) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2568 Fluid - M/T: Fluid Type Specifications MANUAL TRANSMISSION LUBRICANT G56 ...................................................................................................................................................... ........................... Mopar ATF +4 Transmission Fluid Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 2569 Fluid - M/T: Description and Operation MANUAL TRANSMISSION NOTE: DaimlerChrysler recommends using Mopar(R) lubricants or lubricants of equal quality. - Getrag 238 - Mopar(R) ATF+4 Transmission Fluid - G 56 - Mopar(R) ATF+4 Transmission Fluid Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2574 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications CORPORATE AXLES Front Axle C205F OPEN ................................................................................. .................................................................................................. 1.6L (56 oz) Front Axle C200F OPEN ..................................................................................................................... .................................................... 1.7L (57.5 ounces) Front Axle C200FE ANTI-SPIN .............................................................................................................................................................. 1.7L (57.5 ounces) Friction Modifier .................................................................................................... ................................................................................ 4.0 ounces (118 ml) Rear Axle 8.25 OPEN .......................................................................................................................... .................................................... 2.08L (4.4 ounces) Rear Axle 8.25 ANTI-SPIN .................................................................................................................. ...................................................... 2.1L (72 ounces) Friction Modifier ................................................ .................................................................................................................................... 4.0 ounces (118 ml) Rear Axle 9.25 OPEN .......................................................................................................................... ....................................................... 2.2L (74 ounces) Rear Axle 9.25 ANTI-SPIN .................................................................................................................. ...................................................... 2.1L (72 ounces) Friction Modifier ................................................ .................................................................................................................................... 4.0 ounces (118 ml) Rear Axle C213R OPEN ..................................................................................................................... ...................................................... 2.07L (70 ounces) Rear Axle C213RE ANTI-SPIN ......................................................................................................................................................... 2.24L (75.5 ounces) Friction Modifier .................................................................................................. .................................................................................. 4.0 ounces (118 ml) DANA AXLES Front Axle 186 FBI OPEN ............................................................................................ .................................................................................... 1.0L (2.1 Pt) Front Axle 186 FIA OPEN ................................................................................................................... ........................................................... 1.24L (2.6 Pt) Front Axle 216 FBI ANTI-SPIN ............................................................................................................ ........................................................... 1.3L (2.7 Pt) Rear Axle 226 RBI OPEN .................................................................................................................... ......................................................... 2.25L (4.75 Pt) Rear Axle 226 RBI ANTI-SPIN ............................................................................................................ ........................................................ 2.25L (4.75 Pt) Friction Modifier ................................................. ........................................................................................................................................... 0.1 ml (3.4 oz) Rear Axle 226 RIA ANTI-SPIN ............................................................................................................ ....................................................................... 1.35L Rear Axle 302 RBI OPEN .................................................................................................................... .......................................................................... 6.6L Rear Axle 302 RBI ANTI-SPIN ............................................................................................................ ......................................................................... 6.6L AMERICAN AXLES Front Axle 9.25 OPEN ........................................................................................ ........................................................................................................... 2.2L Front Axle 9.25 ANTI-SPIN ................................................................................................................. ......................................................................... 2.0L Rear Axle 10.5 OPEN .......................................................................................................................... ........................................................................... 2.5L Rear Axle 10.5 ANTI-SPIN .................................................................................................................. .......................................................................... 2.5L Rear Axle 11.5 OPEN .......................................................................................................................... ........................................................................... 4.2L Rear Axle 11.5 ANTI-SPIN .................................................................................................................. .......................................................................... 4.0L MAGNA AXLES FRONT AXLE 275 FBI OPEN .................................................................................. .................................................................................................... 5.1L Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2577 Fluid - Differential: Fluid Type Specifications Front and Rear Axles .......................................................................... Synthetic GL-5 SAE 75W-90. 2500/3500 axles do not require limited slip additive. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2582 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Fluid Capacity NV241 GEN II ...................................................................................................................................... ......................................................... 1.6 L ( 3.4 Pt ) NV243 ................................................................ ............................................................................................................................................ 1.6 L ( 3.4 Pt ) NV244 GEN II ............................................................................................................................... ................................................................ 1.6 L ( 3.4 Pt ) NV246 ......................................................... ................................................................................................................................................... 1.9 L ( 4.0 Pt ) NV271 ................................................................................................................................... ....................................................................... 1.89 L ( 4.0 Pt ) NV273 ................................................ .......................................................................................................................................................... 1.89 L ( 4.0 Pt ) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2585 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type All except NVG 246 Automatic Transfer Case Mopar ATF +4, Automatic Transmission Fluid NVG 246 Automatic Transfer Case Only Mopar PN 05179014AA, NVG 246 Automatic Transmission Fluid or equivalent Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Description and Operation > Transfer Case - All Except NV246 Fluid - Transfer Case: Description and Operation Transfer Case - All Except NV246 TRANSFER CASE - ALL EXCEPT NV246 Recommended lubricant for the NV241 GENII, NV271, NV243, NV244 GENII, and NV273 transfer cases is Mopar(R) ATF +4, Automatic Transmission Fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Description and Operation > Transfer Case - All Except NV246 > Page 2588 Fluid - Transfer Case: Description and Operation Transfer Case - NV246 TRANSFER CASE - NV246 Recommended lubricant for the NV246 transfer case is Mopar(R) NVG 246 Automatic Transmission Fluid or equivalent. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Removal 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Installation 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2591 Fluid - Transfer Case: Service and Repair NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Removal 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Installation 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2592 Fluid - Transfer Case: Service and Repair NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Removal 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Installation 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2593 Fluid - Transfer Case: Service and Repair NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2594 Fluid - Transfer Case: Service and Repair NV241 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Removal 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Installation 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV271 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2595 NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Removal 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Installation 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV243 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Removal 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Installation 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV244 GENII Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2596 NOTE: The fill (2) and drain (3) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. 3. Remove drain (3) and fill (2) plugs and drain lubricant completely. 4. Install drain plug (3). Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug (2) to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV246 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (2) and drain (1) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Removal 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 27 Nm (20 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > NV241 GENII Transfer Case > Page 2597 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with the correct fluid for the application. 7. Install and tighten fill plug to 27 Nm (20 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Installation 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. NV273 Transfer Case STANDARD PROCEDURE - FLUID DRAIN AND REFILL The fill (1) and drain (2) plugs are both in the rear case. 1. Raise vehicle. 2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Removal 3. Remove drain and fill plugs and drain lubricant completely. 4. Install drain plug. Tighten plug to 20-34 Nm (15-25 ft. lbs.). 5. Remove drain pan. 6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid. 7. Install and tighten fill plug to 20-34 Nm (15-25 ft. lbs.). 8. Install the exhaust y-pipe to the exhaust manifold, if removed. See: Engine, Cooling and Exhaust/Exhaust System/Exhaust Pipe/Service and Repair/Exhaust Pipe - Installation 9. Wipe any excess fluid that may have spilled onto the exhaust. 10. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2602 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Oil Capacity ......................................................................................................................................... ......................................................... 11.4L (12.0 Qt) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2605 Engine Oil: Fluid Type Specifications Engine Oil ............................................................................................................................................ ............................................................. SAE 15W-40 API CJ-4 Certified, that meets CES 20081 Standards Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2606 Engine Oil: Description and Operation ENGINE OIL - DIESEL ENGINES Use only Low Ash Diesel Engine Oil meeting standard MIL-2104C or API Classification CJ-4/SM (5.9L), or CJ-4 (6.7L), or higher that meets Cummins CES 20081 Standards. Low ash diesel engine oil is REQUIRED for the 6.7L engine, use MOPAR (R) MaxPro15W40 6700 Diesel DPF diesel engine oil, or equivalent. SAE VISCOSITY GRADE CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation. To assure of properly formulated engine oils, it is recommended that SAE Grade 15W-40 engine oils that meet Chrysler material standard MS-10902, be used in accordance to ACEA B3, B4 specification. European Grade 15W-40 oils that meet Association des Constructeurs EuropA■©ens d' Automobiles (European Automobile Manufacturers Association) (ACEA) specifications, are also acceptable. Oils of the SAE 5W-40 grade number are preferred when minimum temperatures consistently fall below -15° C (5° F). ACEA Categories For countries that use the ACEA European Oil Categories for Service Fill Oils, use engine oils that meet the requirements of ACEA A1/B1, A2/B2, or A3/B3. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Service Engine Oil: Service and Repair Engine Oil Service ENGINE OIL SERVICE WARNING: Hot oil can cause personal injury. 1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off. 2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and drain the used engine oil into the container. 3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist. - Thin, black oil indicates fuel dilution. - Milky discoloration indicates coolant dilution. 4. Clean the area around the oil filter head. Remove the filter See: Filters/Oil Filter/Service and Repair/Removal . 5. Install new oil filter See: Filters/Oil Filter/Service and Repair/Installation . 6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface on the oil pan and drain plug. 7. Install the drain plug. Tighten the plug to 50 Nm (37 ft. lbs.) torque. 8. Use only High-Quality Low Ash Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. Choose the correct oil for the operating conditions. 9. Fill the engine with the correct grade of new oil See: . 10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug. 11. Stop engine. Wait 30 minutes to allow the oil to drain back to the pan and check the level again. USED ENGINE OIL DISPOSAL Care should be exercised when disposing of used engine oil after it has been drained from a vehicle's engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Service > Page 2609 Engine Oil: Service and Repair Engine Oil Level ENGINE OIL LEVEL CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE (3) on the engine oil dipstick. NOTE: Note: The best time to check the engine oil level is after the engine is at operating temperature and has been turned off (not running) for 30 minutes. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately 30 minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Replace dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the SAFE RANGE area on the dipstick. 7. Replace dipstick. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2614 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2615 Power Steering Fluid: Specifications POWER STEERING FLUID Mopar ATF +4 Automatic Transmission Fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Description and Operation > Power Steering Fluid Power Steering Fluid: Description and Operation Power Steering Fluid POWER STEERING FLUID Mopar(R) ATF +4, Automatic Transmission Fluid is required in the power steering system. Substitute fluids can induce power steering system failure. Mopar(R) ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Description and Operation > Power Steering Fluid > Page 2618 Power Steering Fluid: Description and Operation Description DESCRIPTION NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar(R) ATF +4. Mopar(R) ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Description and Operation > Page 2619 Power Steering Fluid: Testing and Inspection POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar(R) ATF+4. Do not overfill the power steering system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CHARGE LEVEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2624 Refrigerant: Fluid Type Specifications A/C SYSTEM Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > A/C Refrigerant Refrigerant: Description and Operation A/C Refrigerant A/C REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear and colorless liquefied gas. CAUTION: R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure. The A/C refrigerant system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the charge level should be checked if system performance deteriorates or if a noise or leak is suspected See: Heating and Air Conditioning/Testing and Inspection/Component Tests and General Diagnostics/Refrigerant System Leaks . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 2627 Refrigerant: Description and Operation Description DESCRIPTION The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 2628 Refrigerant: Description and Operation Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > Page 2629 Refrigerant: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing property damage and serious or fatal injury. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs, ventilate work area before resuming service. NOTE: If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location. NOTE: The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuate and recharge the A/C system. Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa (50 psi) See: Heating and Air Conditioning/Tools and Equipment/Refrigerant System Service Equipment . If less than 345 kPa (50 psi), proceed to SYSTEM EMPTY. If greater than 345 kPa (50 psi), go to SYSTEM LOW. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater vacuum) See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate . Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to STEP 2. 2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge and proceed to STEP 1 of the System Low procedure. SYSTEM LOW 3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 4. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5 minutes. - Doors or windows open - Transmission in Park or Neutral with the parking brake set (depending on application) - A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system. 5. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution. Failure to follow the warnings and cautions may result in serious or fatal injury. An R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used to recover the refrigerant from the R-134a refrigerant system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 2632 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery . 2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment See: Heating and Air Conditioning/Tools and Equipment/Refrigerant System Service Equipment . 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 2633 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution. Failure to follow the warnings and cautions may result in serious or fatal injury. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system or the Underhood HVAC Specification Label for the proper amount of the refrigerant charge. See: Heating and Air Conditioning/Specifications/Capacity Specifications . An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. Refer the equipment manufacturer instructions for more information. 1. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate . 2. Connect an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 to the refrigerant system. 3. Refer to A/C SPECIFICATIONS or the Underhood HVAC Specification Label for the proper amount of the refrigerant charge. 4. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 5. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 6. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 7. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch circuits and repair as required. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning may result in serious or fatal injury. 8. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. 9. Disconnect the charging station from the refrigerant system service ports. 10. Reinstall the caps onto the refrigerant system service ports. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2634 Refrigerant: Tools and Equipment REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING: Eye protection must be worn when servicing an A/C refrigerant system. Turn all valves off (rotate clockwise) on the equipment being used before connecting or disconnecting service equipment from the refrigerant system. Failure to observe these warnings may result in personal injury or death. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution. Failure to follow the warnings and cautions could result in possible personal injury or death. When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2210 must be used. Contact an automotive service equipment supplier for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses (4 and 5). This will prevent refrigerant from being released into the atmosphere. MANIFOLD GAUGE SET CONNECTIONS CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible and system damage will result. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Page 2635 RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE - The center manifold hose (Yellow, or White, with Black stripe) (3) is used to recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose. HIGH PRESSURE GAUGE HOSE - The high pressure hose (Red with Black stripe) (4) attaches to the high side service port. This service port is located on the A/C discharge line. On this model, an A/C pressure transducer is installed on the high side service port. A/C high-side pressures can be read using a scan tool. LOW PRESSURE GAUGE HOSE - The low pressure hose (Blue with Black stripe) (5) attaches to the low side service port. This service port is located either on the top of the A/C accumulator or on the A/C suction line near the accumulator, depending on engine application. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the A/C Underhood Specification Label for the correct oil designation. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation (refer to COMPRESSOR OIL DRAIN PROCEDURE). COMPRESSOR OIL DRAIN PROCEDURE CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. The A/C compressor is filled with refrigerant oil from the factory. Use the following procedure to drain and measure refrigerant oil from the A/C compressor. 1. Drain all of the refrigerant oil from the old A/C compressor into a clean measured container. 2. Drain all of the refrigerant oil from the new A/C compressor into a clean measured container. 3. Refill the new A/C compressor with the same amount of refrigerant oil that was drained out of the old compressor. Use only clean refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the new A/C compressor onto the engine See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/A/C Compressor Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2640 Refrigerant Oil: Fluid Type Specifications A/C SYSTEM Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Description Refrigerant Oil: Description and Operation Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the A/C Underhood Specification Label located in the engine compartment). The Denso 10S17 A/C compressor used in this vehicle when equipped with the 3.7L, 4.7L or 5.7L engine is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for these engines. The Visteon HS-18 A/C compressor used in this vehicle when equipped with 5.9L or 6.7L diesel engine is designed to use VC-46 PAG refrigerant oil. Use only this type of refrigerant oil when servicing this A/C compressor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Description > Page 2643 Refrigerant Oil: Description and Operation Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 2644 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the A/C Underhood Specification Label for the correct oil designation. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation (refer to COMPRESSOR OIL DRAIN PROCEDURE). COMPRESSOR OIL DRAIN PROCEDURE CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. The A/C compressor is filled with refrigerant oil from the factory. Use the following procedure to drain and measure refrigerant oil from the A/C compressor. 1. Drain all of the refrigerant oil from the old A/C compressor into a clean measured container. 2. Drain all of the refrigerant oil from the new A/C compressor into a clean measured container. 3. Refill the new A/C compressor with the same amount of refrigerant oil that was drained out of the old compressor. Use only clean refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the new A/C compressor onto the engine See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/A/C Compressor Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 2649 Brake Bleeding: Service and Repair ABS Brake Bleeding ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of a scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding, OR . 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time, OR . 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 2650 Brake Bleeding: Service and Repair Base Brakes - Manual Bleeding MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 2651 Brake Bleeding: Service and Repair Base Brakes - Pressure Bleeding PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 2652 Brake Bleeding: Service and Repair Booster-Hydro-Boost Brake BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) - Diesel Fuse: Locations Fuses (Integrated Power Module) - Diesel FUSES (INTEGRATED POWER MODULE) - DIESEL An integrated Power Module is located in the engine compartment near the battery. This center contains cartridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Underhood Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2658 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2659 CAUTION: - When installing the Integrated Power Module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2660 Fuse: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2661 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel Fuse: Application and ID Fuses (Integrated Power Module) - Diesel FUSES (INTEGRATED POWER MODULE) - DIESEL An integrated Power Module is located in the engine compartment near the battery. This center contains cartridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Underhood Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2682 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2683 CAUTION: - When installing the Integrated Power Module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2684 Fuse: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2685 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > Description Fuse: Description and Operation Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the new vehicle preparation procedures and then disconnect it again until new vehicle delivery to the customer. A laser printed fuse layout map is integral to the TIPM cover to ensure proper fuse identification. The IOD fuse is a 20 ampere mini blade-type fuse. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the TIPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps - Radio - Underhood Lamp Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > Description > Page 2688 Fuse: Description and Operation Operation OPERATION The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) - Diesel Fuse Block: Locations Fuses (Integrated Power Module) - Diesel FUSES (INTEGRATED POWER MODULE) - DIESEL An integrated Power Module is located in the engine compartment near the battery. This center contains cartridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Underhood Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2693 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2694 CAUTION: - When installing the Integrated Power Module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2695 Fuse Block: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2696 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2699 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2700 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2701 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel Fuse Block: Application and ID Fuses (Integrated Power Module) - Diesel FUSES (INTEGRATED POWER MODULE) - DIESEL An integrated Power Module is located in the engine compartment near the battery. This center contains cartridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Underhood Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2717 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2718 CAUTION: - When installing the Integrated Power Module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2719 Fuse Block: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2720 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel Relay Box: Locations Fuses (Integrated Power Module) - Diesel FUSES (INTEGRATED POWER MODULE) - DIESEL An integrated Power Module is located in the engine compartment near the battery. This center contains cartridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Underhood Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2725 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2726 CAUTION: - When installing the Integrated Power Module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2727 Relay Box: Locations Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses (Integrated Power Module) - Diesel > Page 2728 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel Relay Box: Application and ID Fuses (Integrated Power Module) - Diesel FUSES (INTEGRATED POWER MODULE) - DIESEL An integrated Power Module is located in the engine compartment near the battery. This center contains cartridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Underhood Fuses (Integrated Power Module) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2731 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2732 CAUTION: - When installing the Integrated Power Module cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. - When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2733 Relay Box: Application and ID Auxiliary PDC Box (Upfitter Package) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses (Integrated Power Module) - Diesel > Page 2734 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Description Low Tire Pressure Indicator: Description and Operation Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Description > Page 2740 Low Tire Pressure Indicator: Description and Operation Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-ON message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-OFF message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster turns ON the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to TPM indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Technical Service Bulletins > Instruments - Oil Change Indicator System Service Maintenance Required Lamp/Indicator: Technical Service Bulletins Instruments - Oil Change Indicator System Service NUMBER: 08-014-07 GROUP: Electrical DATE: July 11, 2007 SUBJECT: Electronic Vehicle Information Center (EVIC) Oil Change Indicator System Service MODELS: 2008 (DR) Ram Truck 2008 (LX) 300 / Magnum / Charger NOTE: This Bulletin applies to vehicles equipped with a programmable EVIC (sales code LAZ). DISCUSSION: The oil change indicator system is being introduced on most 2008 models. This system displays a "Oil change Required" or "Oil Change" message at appropriate intervals on the instrument cluster. The vehicles listed above may be equipped with a programmable display on the Electronic Vehicle Information Center, (EVIC). The "Oil Change Required" message may also include the dealerships name and phone number which can be programmed into the vehicle with the StarSCAN(R) or StarMOBILE(R) scan tool. The following procedure describes the steps to add, delete or change a dealership name and phone number on the display. NOTE: If NOT programmed during vehicle prep, customer approval MUST be obtained before adding or changing this information. NOTE: When performing this Procedure, the software release level in the StarSCAN(R) or StarMOBILE(R); must be programmed with 8.01 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) or StarMOBILE(R) screen. 1. Connect the StarSCAN(R) or StarMOBILE(R).(in Pass-Through Mode) NOTE: To use the StarMOBILE(R) in Pass-Through Mode requires that StarMOBILE(R) be connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE(R) in Pass-Through Mode, see the StarMOBILE(R) training tutorials available on DealerCONNECT > Service > Repair > StarSCAN(R) and StarMOBILE(R) Tools link or at the website. 2. From the Home Screen, enter "ECU VIEW" or "VEHICLE PREP". 3. Select "CCN". 4. Select "Misc. Functions". 5. Select "Enable/Disable Dealer Contact Information". 6. Select "Enable" or "Disable" as desired. 7. If enabled, select "Program Dealer Contact Information" and follow on screen prompts. 8. "Reset" will cause display to read: "Contact Dealer" as default. 9. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Technical Service Bulletins > Page 2745 Maintenance Required Lamp/Indicator: Service and Repair PERFORM SERVICE INDICATOR - RESET The Perform Service message will display on the EVIC each time you turn the ignition switch to the ON/RUN position to indicate a emission maintenance is required. To reset the Perform Service indicator system (after performing the scheduled maintenance) refer to the following procedure: 1. Turn the ignition switch to the ON position (Do not start engine). 2. Press and release the brake pedal two times. 3. Fully depress the accelerator pedal slowly two times within 10 seconds. 4. Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illumination when you start the vehicle, the Perform Service indicator did not reset. If necessary repeat this procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Description Malfunction Indicator Lamp: Description and Operation Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Description > Page 2750 Malfunction Indicator Lamp: Description and Operation Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-ON message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM or ECM message. For some DTCs, if a problem does not recur, the PCM or ECM will send a lamp-OFF message automatically. Other DTCs may require that a fault be repaired and the PCM or ECM be reset before a lamp-OFF message will be sent. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM or ECM for about 10 seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the EMIC turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to MIL operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Customer Interest for Oil Change Reminder Lamp: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator Oil Change Reminder Lamp: Customer Interest Engine Controls - False Oil Change Indicator NUMBER: 18-005-08 REV. B GROUP: Vehicle Performance DATE: August 20, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-005-08 REV. A, DATED JUNE 13, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.05 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: FLASH: Turn Off Oil Change Indicator Message OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM). MODELS: **2008 (DR) Ram Truck (International Markets)** **2008 (HB) Durango (International Markets)** **2007 - 2008 (JK) Wrangler (International Markets)** **2007 (JK) wrangler** **2008 (KA) Nitro (International Markets)** **2008 (ND) Dakota (International Markets)** 2008 (WH) Grand Cherokee (International Markets) 2008 (XH) Commander (International Markets) NOTE: This bulletin applies to: - **2007 JK vehicles built with a 3.8L engine (sales code EGK) after June 17, 2008 (MDH 0617XX)** - **2008 JK vehicles built with a 3.8L engine (sales code EGK) before April 28, 2008 (MDH 0428XX)** - **2008 DR/HB/ND vehicles built with a 4.7L engine (sales code EVE )** - WK/WH vehicles built with a 4.7L engine (sales code EVE) built before January 25, 2008 (0125XXMDH) - KA vehicles equipped with a 4.0L engine (sales code EGS) built before July 8.2008 (MDH 0708XX) SYMPTOM/CONDITION: Some international vehicle's may experience message on the Electronic Vehicle Information Center (EVIC) or in the Odometer that tells the driver an oil change is necessary after 3000 miles. This message should not be displayed for these international vehicles and this PCM flash will turn this feature off. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If 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, perform the Repair Procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Customer Interest for Oil Change Reminder Lamp: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 2759 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.05 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Customer Interest for Oil Change Reminder Lamp: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 2760 j. Select "Update Controller". k. When the update is complete, select "OK". 7. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Change Reminder Lamp: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator Oil Change Reminder Lamp: All Technical Service Bulletins Engine Controls - False Oil Change Indicator NUMBER: 18-005-08 REV. B GROUP: Vehicle Performance DATE: August 20, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-005-08 REV. A, DATED JUNE 13, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.05 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: FLASH: Turn Off Oil Change Indicator Message OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM). MODELS: **2008 (DR) Ram Truck (International Markets)** **2008 (HB) Durango (International Markets)** **2007 - 2008 (JK) Wrangler (International Markets)** **2007 (JK) wrangler** **2008 (KA) Nitro (International Markets)** **2008 (ND) Dakota (International Markets)** 2008 (WH) Grand Cherokee (International Markets) 2008 (XH) Commander (International Markets) NOTE: This bulletin applies to: - **2007 JK vehicles built with a 3.8L engine (sales code EGK) after June 17, 2008 (MDH 0617XX)** - **2008 JK vehicles built with a 3.8L engine (sales code EGK) before April 28, 2008 (MDH 0428XX)** - **2008 DR/HB/ND vehicles built with a 4.7L engine (sales code EVE )** - WK/WH vehicles built with a 4.7L engine (sales code EVE) built before January 25, 2008 (0125XXMDH) - KA vehicles equipped with a 4.0L engine (sales code EGS) built before July 8.2008 (MDH 0708XX) SYMPTOM/CONDITION: Some international vehicle's may experience message on the Electronic Vehicle Information Center (EVIC) or in the Odometer that tells the driver an oil change is necessary after 3000 miles. This message should not be displayed for these international vehicles and this PCM flash will turn this feature off. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If 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, perform the Repair Procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Change Reminder Lamp: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 2766 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.05 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Change Reminder Lamp: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 2767 j. Select "Update Controller". k. When the update is complete, select "OK". 7. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Description Oil Change Reminder Lamp: Description and Operation Description DESCRIPTION A change oil indicator is standard equipment on all instrument clusters. However, on vehicles manufactured for export markets or vehicles equipped with the optional diesel engine, this indicator is electronically disabled. The change oil indication appears within the odometer Vacuum Fluorescent Display (VFD) unit. The change oil indicator consists of cycling textual CHAngE and OIL messages which appear in place of the odometer information in the odometer display. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The change oil textual messages appear in the same blue-green color and at the same lighting level as the odometer information when they are illuminated by the instrument cluster electronic circuit board. The change oil indicator is serviced as a unit with the VFD in the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Description > Page 2770 Oil Change Reminder Lamp: Description and Operation Operation OPERATION The change oil indicator gives an indication to the vehicle operator when a duty-cycle algorithm contained within the software of the Powertrain Control Module (PCM) determines that a recommended oil change interval has been attained. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the PCM. The change oil indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the odometer VFD change oil indication will always be OFF when the ignition switch is in any position except ON or START. The instrument cluster will turn ON the change oil indicator for the following reasons: - Change Oil Indicator Lamp-On Message - Each time the ignition switch is turned to the ON position and the cluster receives an electronic change oil indicator lamp-ON message from the PCM indicating that a duty-cycle based recommended oil change interval has been attained, the change oil indicator will be illuminated for about three seconds, until the trip odometer reset switch button is depressed, or until the ignition switch is turned to the OFF position, whichever occurs first. - Change Oil Indicator Reset Procedure - Once an engine oil change has been completed, the PCM duty cycle counters can be reset using the following procedure. Turn the ignition switch to the ON position, but DO NOT start the engine. Slowly depress and release the accelerator pedal fully three times within ten seconds. Turn the ignition switch to the OFF position. If the change oil indicator illuminates the next time the engine is started, repeat this procedure. The PCM continually monitors numerous sensor inputs to determine the duty-cycles to which the engine is being subjected. A pre-programmed algorithm within the PCM then determines when to send the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For proper diagnosis of the change oil indicator, the PCM, the EMIC, the CAN data bus or the electronic communication related to change oil indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 2771 Oil Change Reminder Lamp: Service and Repair OIL CHANGE INDICATOR - RESET To reset the "Oil Change Required" indicator (after performing the scheduled maintenance) refer to the following procedure: - 1. Turn the ignition switch to the ON position (Do not start engine). - 2. Fully depress the accelerator pedal slowly three times within 10 seconds. - 3. Turn the ignition switch to the OFF/LOCK position. NOTE: If the "Oil Change Required" indicator message illuminates when you start the vehicle, the indicator did not reset. If necessary repeat this procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair STANDARD PROCEDURE WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. FLOOR JACK When properly positioned, a floor jack can be used to lift a vehicle. Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2776 CAUTION: Do not lift vehicle with a floor jack positioned under: - An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. NOTE: Use the correct front frame rail lifting locations only. NOTE: Use the correct rear frame rail lifting locations only. HOIST Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2777 A vehicle can be lifted with: - A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly. NOTE: The forward lifting pads should be positioned against the forward flange of the transmission crossmember brackets at the bottom of the frame rail. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2778 NOTE: The rear lifting pads should be wedged between the forward flange of the leaf spring bracket and the frame rail. Safety stands should be placed under the frame rails at the front and rear ends. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID 521 Component ID: 521 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-- Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2784 Component ID 523 Component ID: 523 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2785 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2786 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Front Component ID 522 Component ID: 522 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-- Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2787 Component ID 524 Component ID: 524 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2788 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID 521 Component ID: 521 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-- Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2791 Component ID 523 Component ID: 523 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2792 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2793 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Front Component ID 522 Component ID: 522 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-- Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2794 Component ID 524 Component ID: 524 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2795 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder (2), also known as a trigger module, is located in the front wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the front tire pressure sensors on the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 2798 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION The Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in the front wheel wells on the vehicle to provide it with the location of the front tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 20 minutes or longer). If the TPMS fails to localize, the TPM indicator lamp will flash on/off for 75 seconds, and remain on solid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > TPM Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair TPM Transponder - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel well housing cover. 3. Remove the mounting screw (1) for the transponder (2). 4. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > TPM Transponder - Removal > Page 2801 Tire Pressure Monitor Receiver / Transponder: Service and Repair TPM Transponder - Installation INSTALLATION 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3). 2. Install the mounting screw (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover. 4. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is not recommended for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants may clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: It is not recommended to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor (6) must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a GREEN sensor body, with (an triangle insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. For car applications, there is a 315 MHz TPM sensor with a Black sensor body with an oval insignia. NOTE: This vehicle uses the 315 MHz TPM sensor with the GREEN sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues.) The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 2808 Tire Pressure Sensor: Description and Operation Operation OPERATION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, nut, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The High Pressure TPM sensor can be in one of the following modes: Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 2 psi (13.8 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 2 psi (13.8 kPA) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 Block Mode - If the vehicle has not been moving for more then 20 minutes, or if the sensor's mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After 8 minutes of continuous driving above 15 mph (24 km/h), the TPM sensor will change to DRIVE MODE. Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Page 2809 Tire Pressure Sensor: Testing and Inspection TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. NOTE: Tire pressure will vary with temperature by about 1 psi (6.9 kPa) for every 12 F (6.5 C). This means that when the outside temperature decreases, the tire pressure will also decrease. Tire pressure should always be set based on cold inflation tire pressure. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire on the vehicle, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for leaks around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. If the indicator lamp is flashing on/off for 75 seconds and then remains on solid, a system fault was detected. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove the tire and wheel assembly. See: Service and Repair/Removal and Replacement CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Let the air out of the tire. 4. Remove the nut (3). 5. Push the sensor into the tire (1) (so the sensor is loose inside the tire). 6. Remove the tire from the rim. 7. Retrieve the sensor (1) from the tire. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 2812 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor (6), replace valve cap (2), nut (3), valve core and sensor seal (4) to ensure proper sealing. NOTE: The notch/flat should be lined up together and facing towards the wheel during installation. 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Damage to the sensor may occur if the sensor is installed incorrectly. NOTE: A flat on the seal seat is used to key the seat to the sensor housing. The notch/flat should be lined up together and facing towards the wheel during installation. 3. Install sensor nut (3) and hand tighten. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-tightening the sensor to as much as 10 Nm (88 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturer's instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 2813 Rotating Wheel Tire Changers- Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 180° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 180° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. See: Service and Repair/Removal and Replacement 8. Lower vehicle. 9. If the vehicle has been stationary for more then 20 minutes, drive the vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. A new sensor ID can also be programmed directly into the WCM by using a RKE-TPM Analyzer in conjunction with a Scan Tool. Once the new sensor ID has been programmed, the RKE-TPM Analyzer can be used to update the TPMS by activating the sensor. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations Tire Pressure Warning Reset Switch: Locations Component ID: 513 Component : SWITCH-TIRE PRESSURE MONITOR Connector: Name : SWITCH-TIRE PRESSURE MONITOR Color : BROWN # of pins : 6 Pin Circuit Description 1 G561 20VT TPM INDICATOR CONTROL 2 E11 20OR/DB PANEL LAMPS DRIVER 3 G562 20VT/YL TPM SWITCH SIGNAL 4 Z600 20BK GROUND 5 F504 20GY/PK NO FUNCTION DEFINED 6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 2817 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 2818 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 2819 Tire Pressure Warning Reset Switch: Diagrams Component ID: 513 Component : SWITCH-TIRE PRESSURE MONITOR Connector: Name : SWITCH-TIRE PRESSURE MONITOR Color : BROWN # of pins : 6 Pin Circuit Description 1 G561 20VT TPM INDICATOR CONTROL 2 E11 20OR/DB PANEL LAMPS DRIVER 3 G562 20VT/YL TPM SWITCH SIGNAL 4 Z600 20BK GROUND 5 F504 20GY/PK NO FUNCTION DEFINED 6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 2820 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description Low Tire Pressure Indicator: Description and Operation Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Description > Page 2826 Low Tire Pressure Indicator: Description and Operation Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-ON message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-OFF message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster turns ON the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the electronic communication related to TPM indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front Component ID 521 Component ID: 521 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-- Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2831 Component ID 523 Component ID: 523 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2832 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2833 Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Front Component ID 522 Component ID: 522 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-- Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2834 Component ID 524 Component ID: 524 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 2835 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front Component ID 521 Component ID: 521 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-- Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2838 Component ID 523 Component ID: 523 Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2839 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4 Z924 20BK GROUND 5-6-Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2840 Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Front Component ID 522 Component ID: 522 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-- Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2841 Component ID 524 Component ID: 524 Component : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Connector: Name : TRANSPONDER-TIRE PRESSURE-RIGHT FRONT Color : # of pins : 6 Pin Circuit Description Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 2842 1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) 2 D508 20WT/GY COM-LIN TIRE PRESSURE MONITOR LAN 3 Z924 20BK GROUND 4-5 Z924 20BK GROUND 6-Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Description DESCRIPTION A transponder (2), also known as a trigger module, is located in the front wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the front tire pressure sensors on the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 2845 Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation OPERATION The Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in the front wheel wells on the vehicle to provide it with the location of the front tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 20 minutes or longer). If the TPMS fails to localize, the TPM indicator lamp will flash on/off for 75 seconds, and remain on solid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > TPM Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair TPM Transponder - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel well housing cover. 3. Remove the mounting screw (1) for the transponder (2). 4. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > TPM Transponder - Removal > Page 2848 Tire Pressure Monitor Receiver / Transponder: Service and Repair TPM Transponder - Installation INSTALLATION 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3). 2. Install the mounting screw (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover. 4. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is not recommended for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants may clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: It is not recommended to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description Tire Pressure Sensor: Description and Operation Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor (6) must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a GREEN sensor body, with (an triangle insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. For car applications, there is a 315 MHz TPM sensor with a Black sensor body with an oval insignia. NOTE: This vehicle uses the 315 MHz TPM sensor with the GREEN sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues.) The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Description > Page 2854 Tire Pressure Sensor: Description and Operation Operation OPERATION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, nut, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The High Pressure TPM sensor can be in one of the following modes: Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 2 psi (13.8 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 2 psi (13.8 kPA) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 Block Mode - If the vehicle has not been moving for more then 20 minutes, or if the sensor's mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After 8 minutes of continuous driving above 15 mph (24 km/h), the TPM sensor will change to DRIVE MODE. Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Page 2855 Tire Pressure Sensor: Testing and Inspection TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. NOTE: Tire pressure will vary with temperature by about 1 psi (6.9 kPa) for every 12 F (6.5 C). This means that when the outside temperature decreases, the tire pressure will also decrease. Tire pressure should always be set based on cold inflation tire pressure. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire on the vehicle, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for leaks around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. If the indicator lamp is flashing on/off for 75 seconds and then remains on solid, a system fault was detected. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal Tire Pressure Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Remove the tire and wheel assembly. See: Service and Repair/Removal and Replacement CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Let the air out of the tire. 4. Remove the nut (3). 5. Push the sensor into the tire (1) (so the sensor is loose inside the tire). 6. Remove the tire from the rim. 7. Retrieve the sensor (1) from the tire. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 2858 Tire Pressure Sensor: Service and Repair Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor (6), replace valve cap (2), nut (3), valve core and sensor seal (4) to ensure proper sealing. NOTE: The notch/flat should be lined up together and facing towards the wheel during installation. 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Damage to the sensor may occur if the sensor is installed incorrectly. NOTE: A flat on the seal seat is used to key the seat to the sensor housing. The notch/flat should be lined up together and facing towards the wheel during installation. 3. Install sensor nut (3) and hand tighten. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-tightening the sensor to as much as 10 Nm (88 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturer's instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page 2859 Rotating Wheel Tire Changers- Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 180° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the upper and lower tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 180° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. See: Service and Repair/Removal and Replacement 8. Lower vehicle. 9. If the vehicle has been stationary for more then 20 minutes, drive the vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. A new sensor ID can also be programmed directly into the WCM by using a RKE-TPM Analyzer in conjunction with a Scan Tool. Once the new sensor ID has been programmed, the RKE-TPM Analyzer can be used to update the TPMS by activating the sensor. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Warning Reset Switch > Component Information > Locations Tire Pressure Warning Reset Switch: Locations Component ID: 513 Component : SWITCH-TIRE PRESSURE MONITOR Connector: Name : SWITCH-TIRE PRESSURE MONITOR Color : BROWN # of pins : 6 Pin Circuit Description 1 G561 20VT TPM INDICATOR CONTROL 2 E11 20OR/DB PANEL LAMPS DRIVER 3 G562 20VT/YL TPM SWITCH SIGNAL 4 Z600 20BK GROUND 5 F504 20GY/PK NO FUNCTION DEFINED 6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 2863 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 2864 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 2865 Tire Pressure Warning Reset Switch: Diagrams Component ID: 513 Component : SWITCH-TIRE PRESSURE MONITOR Connector: Name : SWITCH-TIRE PRESSURE MONITOR Color : BROWN # of pins : 6 Pin Circuit Description 1 G561 20VT TPM INDICATOR CONTROL 2 E11 20OR/DB PANEL LAMPS DRIVER 3 G562 20VT/YL TPM SWITCH SIGNAL 4 Z600 20BK GROUND 5 F504 20GY/PK NO FUNCTION DEFINED 6-Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Warning Reset Switch > Component Information > Locations > Page 2866 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications Tires: Specifications TIRE REVOLUTIONS PER MILE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Spare Tire Tires: Description and Operation Spare Tire Spare / Temporary Tire SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 KMH (50 MPH). when using the temporary spare tire. Full Size, Spare Wheel With Matching Tire FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire, It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Spare Tire > Page 2872 Tires: Description and Operation Pressure Gauges PRESSURE GAUGES A quality air pressure gauge is recommended to check tire pressure. After checking the air pressure, replace valve cap finger tight. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Spare Tire > Page 2873 Tires: Description and Operation Tires - Description Tires TIRES Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval See: Service and Repair/Procedures . This will help to achieve a greater tread life. TIRE IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: - Q up to 99 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph V up to 149 mph W (consult the tire manufacturer for the specific speed rating) - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Radial - Ply Tires RADIAL - PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Spare Tire > Page 2874 Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 KMH (50 MPH) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Tire Pressure For High Speeds TIRE PRESSURE FOR HIGH SPEEDS For proper tire pressure specification refer to the Owners Manual. Tire Inflation Pressures TIRE INFLATION PRESSURES WARNING: Over or under inflated tires can affect vehicle handling and tread wear. This may cause the tire to fail suddenly, resulting in loss of vehicle control. Under inflation will cause rapid shoulder wear (1), tire flexing, and possible tire failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Spare Tire > Page 2875 Over inflation will cause rapid center wear (1) reduction in the tire's ability to cushion shocks. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the tire label placard usually located on the drivers door latch pillar. Spare / Temporary Tire SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 KMH (50 MPH). when using the temporary spare tire. Replacement Tires REPLACEMENT TIRES The original equipment tires provide a proper balance of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators (3) are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators (3) will appear as a 13 mm (1/2 in.) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 2878 Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 2879 Tires: Testing and Inspection Tire Noise Or Vibration TIRE NOISE OR VIBRATION Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing the noise or vibration, drive the vehicle over a smooth road at varying speeds. Note the noise level during acceleration and deceleration. The engine, differential and exhaust noises will change as speed varies, while the tire noise will usually remain constant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tread Wear Indicators > Page 2880 Tires: Testing and Inspection Tire / Vehicle Lead TIRE/VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Correction Chart to diagnose and correct a vehicle lead or drift problem. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures TIRES Remove the protective coating on the tires before delivery of a vehicle. This coating may cause deterioration of the tires. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. NOTE: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 2883 Tires: Removal and Replacement TIRE REPAIR AREA For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before removing the tire from the wheel. Use lubrication such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and tighten to proper torque specification. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 2888 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Wheel Design Wheels: Description and Operation Wheel Design WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Wheel Design > Page 2891 Wheels: Description and Operation Wheels WHEELS Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, the rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 2892 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. Used wheels are not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: Daimlerchrysler corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For Clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal Wheel Bearing: Service and Repair Front Hub / Bearing - Removal 4X4 - Independent Front Suspension 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal . 4. Remove the ABS wheel speed sensor if equipped, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor - Removal . 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using remover 9360. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using remover 9360. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. 2500 & 3500 - 4WD - Link/Coil 2500 & 3500 - 4WD 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the hub extension (1) mounting nuts and remove the extension from the rotor if equipped. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 2898 4. Remove the brake caliper, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Removal . 5. Remove the cotter pin (2) and the hub nut (1) from the axle shaft. 6. Remove the caliper adapter. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Removal . 7. Remove the disc brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal . 8. Disconnect the wheel speed sensor wire. 9. Remove the hub/bearing 4 mounting bolts and remove the hub/bearing. 4500 & 5500 - Link/Coil 4500 & 5500 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Removal . 4. Remove the caliper adapter. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Removal . 5. Remove the hub extension (2) and disc brake rotor (1) See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal . 6. Remove the axle shaft nut (3) from the axle shaft. 7. Disconnect the wheel speed sensor wire and remove the wheel speed sensor bolt (1) from the hub/bearing then remove the sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 2899 8. Remove the hub/bearing 4 mounting bolts (1) and remove the hub/bearing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 2900 Wheel Bearing: Service and Repair Front Hub / Bearing - Installation 4X4 - Independent Front Suspension 4X4 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation . 4. Install the ABS wheel speed sensor if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor - Installation . 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly See: Service and Repair/Removal and Replacement . 9. Remove the support and lower vehicle. 2500 & 3500 - 4WD - Link/Coil 2500 & 3500 - 4WD 1. Position the brake shield (1) on bolts. 2. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (2) to 202 Nm (149 ft. lbs. 3. Install the hub nut and tighten to 356 Nm (263 ft. lbs.). 4. Install the wheel speed sensor to the hub. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor - Installation . 5. Install the disc brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 2901 6. Install the brake caliper adapter with the caliper, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Installation . 7. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). HD DRW ONLY. 8. Install the wheel and tire assemblies, See: Service and Repair/Removal and Replacement . 9. Remove the support and lower the vehicle. 10. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. 4500 & 5500 - Link/Coil 4500 & 5500 NOTE: If installing a NEW hub/bearing on a 4X4 only Steps 1-3 should be followed for the correct shim size. 1. Measure from the new hub/bearing unit crimp (2) to the flange (3). 2. Choose the correct shim according to the table: 3. Check the shim (2) on the axle shaft (3). Be sure that the shim (2) is placed with the radius side (1) to the joint. 4. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (1) to 202 Nm (149 ft. lbs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 2902 5. Install the axle nut (3) and tighten to 356 Nm (263 ft. lbs.). 6. Install the wheel speed sensor 2) to the hub and tighten the bolt (1). See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor - Installation . 7. Install the disc brake rotor (1). See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation . 8. Install the hub extension (2) and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). 9. Install the brake caliper adapter with the caliper, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Installation . 10. Install the wheel and tire assemblies, See: Service and Repair/Removal and Replacement . 11. Remove the support and lower the vehicle. 12. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal Wheel Cover: Service and Repair Removal REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with dual rear wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. NOTE: Failure to use a back and forth motion could damage the wheel skin chrome finish. 4. The wheel skins can now be removed from the wheel. Use the flat end of the lug nut wrench to pry off the wheel skins. Make sure that the flat end is inserted and use a back and forth motion to remove the wheel skin. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Removal > Page 2907 Wheel Cover: Service and Repair Installation Front FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistant gap between the skin/ cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Rear REAR 1. Install one 1 1/2 in. valve stem extension on each rear inner wheel. NOTE: A 3/8 in. drive 10mm deep wheel socket with a 10 in. or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 in. valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike thew wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > 4X4 - Independent Front Suspension Axle Nut: Specifications 4X4 - Independent Front Suspension 4X4 Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > 4X4 - Independent Front Suspension > Page 2913 Axle Nut: Specifications 2500 & 3500 - 4WD - Link/Coil 2500 & 3500 - 4WD Install the hub nut and tighten to 356 Nm (263 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > 4X4 - Independent Front Suspension > Page 2914 Axle Nut: Specifications 4500 & 5500 - Link/Coil 4500 & 5500 Install the axle nut (3) and tighten to 356 Nm (263 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE Torque Specifications Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Removal Wheel Fastener: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal . 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using remover C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Removal > Page 2920 Wheel Fastener: Service and Repair Installation INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation . 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair Jump Starting: Service and Repair STANDARD PROCEDURE WARNING: review all safety precautions and warnings in the battery system section. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Charging - Do not jump start a frozen battery, personal injury can result. - If equipped, do not jump start when maintenance free battery indicator dot is yellow or bright color. - Do not jump start a vehicle when the battery fluid is below the top of lead plates. - Do not allow jumper cable clamps to touch each other when connected to a booster source. - Do not use open flame near battery. - Remove metallic jewelry worn on hands or wrists to avoid injury by accidental arcing of battery current. - When using a high output boosting device, do not allow battery voltage to exceed 16 volts. Failure to follow these instructions may result in personal injury. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. TO JUMP START A DISABLED VEHICLE: 1. Raise hood on disabled vehicle and visually inspect engine compartment for: - Battery cable clamp condition, clean if necessary. - Frozen battery. - Yellow or bright color test indicator, if equipped. - Low battery fluid level. - Generator drive belt condition and tension. - Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. 2. When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. 3. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. 4. Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. 5. On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible. 6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. 7. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min.), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: - Disconnect BLACK cable clamp from engine ground on disabled vehicle. - When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. - Disconnect RED cable clamp from battery positive terminal on disabled vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing Towing Information: Service and Repair Towing STANDARD PROCEDURE A vehicle equipped with SAE approved sling-type towing equipment can be used to tow all vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with flat-bed device can also be used to transport a disabled vehicle. A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method. SAFETY PRECAUTIONS CAUTION: The following safety precautions must be observed when towing a vehicle: - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Do not tow a heavily loaded vehicle. Damage to the cab, cargo box or frame may result. Use a flatbed device to transport a loaded vehicle. GROUND CLEARANCE CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors. A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain or steep rises in the road. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums or rotors. RAMP ANGLE If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees. TOWING WHEN KEYS ARE NOT AVAILABLE When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used on 4WD vehicles provided all the wheels are lifted off the ground using tow dollies. FOUR-WHEEL-DRIVE VEHICLE TOWING DaimlerChrysler Corporation recommends that a vehicle be transported on a flat-bed device. A Wheel-lift or Sling-type device can be used provided all Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2928 the wheels are lifted off the ground using tow dollies. WARNING: When towing a disabled vehicle and the drive wheels are secured in a wheel lift or tow dollies, ensure the transmission is in the park position (automatic transmission) or a forward drive gear (manual transmission). CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2929 Towing Information: Service and Repair Trailer Towing - NAFTA TRAILER TOWING - NAFTA In this section you will find safety tips and information on limits to the type of towing you can reasonably do with your vehicle. Before towing a trailer carefully review this information to tow your load as efficiently and safely as possible. To maintain warranty coverage, follow the requirements and recommendations concerning vehicles used for trailer towing. Common Towing Definitions The following trailer towing related definitions will assist you in understanding the following information: Gross Vehicle Weight Rating (GVWR) The GVWR is the total allowable weight of your vehicle. This includes driver, passengers, cargo and tongue weight. The total load must be limited so that you do not exceed the GVWR. Gross Trailer Weight (GTW) The gross trailer weight (GTW) is the weight of the trailer plus the weight of all cargo, consumables and equipment (permanent or temporary) loaded in or on the trailer in its "loaded and ready for operation" condition. The recommended way to measure GTW is to put your fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale. Gross Combination Weight Rating (GCWR) The gross combination weight rating (GCWR) is the total permissible weight of your vehicle and trailer when weighed in combination. (Note that GCWR ratings include a 68 kg (150 lbs) allowance for the presence of a driver). Gross Axle Weight Rating (GAWR) The GAWR is the maximum capacity of the front and rear axles. Distribute the load over the front and rear axles evenly. Make sure that you do not exceed either front or rear GAWR. WARNING: It is important that you do not exceed the maximum front or rear GAWR. A dangerous driving condition can result if either rating is exceeded. You could lose control of the vehicle and have an accident. Tongue Weight (TW) The downward force exerted on the hitch ball by the trailer. In most cases it should not be less than 10% or more than 15% of the trailer load. You must consider this as part of the load on your vehicle. Frontal Area The maximum height and maximum width of the front of a trailer. Trailer Sway Control The trailer sway control is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associated with the telescoping motion to dampen any unwanted trailer swaying motions while traveling. Weight-Carrying Hitch A weight-carrying hitch supports the trailer tongue weight, just as if it were luggage located at a hitch ball or some other connecting point of the truck. These kind of hitches are the most popular on the market today and they're commonly used to tow small- and medium-sized trailers. Weight-Distributing Hitch A weight-distributing system works by applying leverage through spring (load) bars. They are typically used for heavier loads, to distribute trailer tongue weight to the tow vehicle's front axle and the trailer axle(s). When used in accordance with the manufacturers' directions, it provides for a more level ride, offering more consistent steering and brake control thereby enhancing towing safety. The addition of a friction / hydraulic sway control also dampens sway caused by traffic and crosswinds and contributes positively to tow vehicle and trailer stability. Trailer sway control and a weight distributing (load equalizing) hitch are recommended for heavier Tongue Weights (TW) and may be required depending on Vehicle and Trailer configuration / loading to comply with gross axle weight rating (GAWR) requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2930 WARNING: An improperly adjusted Weight Distributing Hitch system may reduce handling, stability, braking performance, and could result in an accident. Weight Distributing Systems may not be compatible with Surge Brake Couplers. Consult with your hitch and trailer manufacturer or a reputable Recreational Vehicle dealer for additional information. Fifth-Wheel Hitch A special high platform with a coupling that mounts over the rear axle of the tow vehicle in the truck bed. Connects a vehicle and fifth-wheel trailer with a coupling king pin. Gooseneck Hitch The gooseneck hitch employs a pivoted coupling arm which attaches to a ball mounted in the bed of a pickup truck. The coupling arm connects to the hitch mounted over the rear axle in the truck bed. Trailer Hitch Classification The rear bumper is intended to tow trailers up to 2,000 lbs (907 kg) without added equipment or alterations to the standard equipment. Your vehicle may be factory equipped for safe towing of trailers weighing over 2,000 lbs (907 kg) with the optional Trailer Tow Prep Package. See your dealer for package content. The following chart provides the industry standard for the maximum trailer weight a given trailer hitch class can tow and should be used to assist you in selecting the correct trailer hitch for your intended towing condition. All trailer hitches should be professionally installed on your vehicle. Trailer Towing Weights (Maximum Trailer Weight Ratings) Trailer and Tongue Weight Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2931 Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the Gross Trailer Weight (GTW) on the tow hitch of your vehicle. Loads balanced over the wheels or heavier in the rear can cause the trailer to swayseverely side to side which will cause loss of control of vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents. Never exceed the maximum tongue weight stamped on your bumper or trailer hitch. Consider the following items when computing the weight on the rear axle of the vehicle: - The tongue weight of the trailer. - The weight of any other type of cargo or equipment put in or on your vehicle. - The weight of the driver and all passengers. NOTE: Remember that everything put into or on the trailer adds to the load on your vehicle. Also, additional factory-installed options, or dealer-installed options, must be considered as part of the total load on your vehicle. Towing Requirements To promote proper break-in of your new vehicle drivetrain components the following guidelines are recommended: CAUTION: - Avoid towing a trailer for the first 500 miles (805 km) of vehicle operation. Doing so may damage your vehicle. - During the first 500 miles (805 km) of trailer towing, limit your speed to 50 mph (80 km/h). WARNING: Your vehicle may require special axle lubricant. Perform the maintenance listed of this manual. When towing a trailer, never exceed the GAWR, or GCWR, ratings. WARNING: Improper towing can lead to an injury accident. Follow these guidelines to make your trailer towing as safe as possible: Make certain that the load is secured in the trailer and will not shift during travel. When trailering cargo that is not fully secured, dynamic load shifts can occur that may be difficult for the driver to control. You could lose control of your vehicle and have an accident. - When hauling cargo or towing a trailer, do not overload your vehicle or trailer. Overloading can cause a loss of control, poor performance or damage to brakes, axle, engine, transmission, steering, suspension, chassis structure or tires. - Safety chains must always be used between your vehicle and trailer. Always connect the chains to the frame or hook retainers of the vehicle hitch. Cross the chains under the trailer tongue and allow enough slack for turning corners. - Vehicles with trailers should not be parked on a grade. When parking, apply the parking brake on the tow vehicle. Put the tow vehicle automatic transmission in P for Park. With a manual transmission, shift the transmission into reverse. And with four-wheel-drive vehicles, make sure the transfer case is not in neutral. Always, block or "chock" the trailer wheels. - GCWR must not be exceeded. - Total weight must be distributed between the tow vehicle and the trailer such that the following four ratings are not exceeded: - GVWR - GTW - GAWR - Tongue weight rating for the trailer hitch utilized (This requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight). Towing Requirements - Tires - Do not attempt to tow a trailer while using a compact spare tire. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2932 - Proper tire inflation pressures are essential to the safe and satisfactory operation of your vehicle. - Also, check the trailer tires for proper tire inflation pressures before trailer usage. - Check for signs of tire wear or visible tire damage before towing a trailer. - When replacing tires, Replacing tires with a higher load carrying capacity will not increase the vehicle's GVWR and GAWR limits. Towing Requirements - Trailer Brakes - Do not interconnect the hydraulic brake system or vacuum system of your vehicle with that of the trailer. This could cause inadequate braking and possible personal injury. - An electronically actuated trailer brake controller is required when towing a trailer with electronically actuated brakes. When towing a trailer equipped with a hydraulic surge actuated brake system, an electronic brake controller is not required. - Trailer brakes are recommended for trailers over 1,000 lbs (454 kg) and required for trailers in excess of 2,000 lbs (907 kg). CAUTION: If the trailer weighs more than 1,000 lbs (454 kg) loaded, it should have its own brakes and they should be of adequate capacity. Failure to do this could lead to accelerated brake lining wear, higher brake pedal effort, and longer stopping distances. WARNING: Do not connect trailer brakes to your vehicle's hydraulic brake lines. It can overload your brake system and cause it to fail. You might not have brakes when you need them and could have an accident. Towing any trailer will increase your stopping distance. When towing you should allow for additional space between your vehicle and the vehicle in front of you. Failure to do so could result in an accident. Towing Requirements - Trailer Lights & Wiring Whenever you pull a trailer, regardless of the trailer size, stop lights and turn signals on the trailer are required for motoring safety. The Trailer Tow Package may include a 4 and 7 pin wiring harness. Use a factory approved trailer harness and connector. NOTE: Do not cut or splice wiring into the vehicles wiring harness. The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the following illustrations. Towing Tips Before setting out on a trip, practice turning, stopping and backing the trailer in an area away from heavy traffic. If using a manual transmission vehicle for trailer towing, all starts must be in FIRST gear to avoid excessive clutch slippage. Towing Tips - Automatic Transmission Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2933 The "D" range can be selected when towing. However, if frequent shifting occurs while in this range, the "TOW HAUL" or "OD/OFF" range should be selected. NOTE: Using the "TOW HAUL" or "OD/OFF" range while operating the vehicle under heavy operating conditions will improve performance and extend transmission life by reducing excessive shifting and heat build up. This action will also provide better engine braking. The automatic transmission fluid and filter should be changed if you REGULARLY tow a trailer for more than 45 minutes of continuous operation. NOTE: Check the automatic transmission fluid level before towing. Towing Tips - Tow/Haul (If Equipped) To reduce potential for automatic transmission overheating, turn the "TOW HAUL OD/OFF" feature ON when driving in hilly areas or shift the transmission to Drive position 2 on more severe grades. Towing Tips - Electronic Speed Control (If Equipped) - Don't use in hilly terrain or with heavy loads. - When using the speed control, if you experience speed drops greater than 10 mph (16 km/h), disengage until you can get back to cruising speed. - Use speed control in flat terrain and with light loads to maximize fuel efficiency. Towing Tips - Cooling System To reduce potential for engine and transmission overheating, take the following actions: - City Driving - When stopped for short periods of time, put transmission in neutral and increase engine idle speed. - Highway Driving - Reduce speed. - Air Conditioning - Turn off temporarily. - refer to Cooling System Operating information in the Maintenance section of this manual for more information. Trailer Towing Mirrors - If Equipped These mirrors are designed with an adjustable mirror head to provide a greater vision range when towing extra-wide loads. To change position inboard or outboard, the mirror head should be rotated (flipped Out or In). A small blindspot mirror is integrated onto the main mirror surface. NOTE: Fold the 7 x 10 inch trailer towing mirrors rearward prior to entering an automated car wash. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair STANDARD PROCEDURE WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. FLOOR JACK When properly positioned, a floor jack can be used to lift a vehicle. Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2937 CAUTION: Do not lift vehicle with a floor jack positioned under: - An axle tube. - A body side sill. - A steering linkage component. - A drive shaft. - The engine or transmission oil pan. - The fuel tank. - A front suspension arm. NOTE: Use the correct front frame rail lifting locations only. NOTE: Use the correct rear frame rail lifting locations only. HOIST Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2938 A vehicle can be lifted with: - A single-post, frame-contact hoist. - A twin-post, chassis hoist. - A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly. NOTE: The forward lifting pads should be positioned against the forward flange of the transmission crossmember brackets at the bottom of the frame rail. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2939 NOTE: The rear lifting pads should be wedged between the forward flange of the leaf spring bracket and the frame rail. Safety stands should be placed under the frame rails at the front and rear ends. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Specifications Compression Ratio .............................................................................................................................. ....................................................................... 17.2 : 1 Compression Pressure (Minimum) ...................................................................................................... ....................................................................... 350 psi Max Variation Between Cylinders ........................................................................................................ ............................................................ Not available Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures INSPECTION Camshaft 1. Inspect the valve lobes (1) and bearing journals (2) for cracks, pitting, scoring, or generally excessive wear. Replace any camshaft that exceeds the allowable limits. 2. Measure the bearing journals and lobes. CAUTION: If Camshaft lobes are worn, requiring camshaft replacement, it is necessary to replace the tappets also. See: Lifter / Lash Adjuster/Service and Repair/Removal and Replacement/Valve Tappet(s) - Removal. Camshaft Bushing/Bores Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2950 Camshaft bores No. 2-6 do not use a bushing. 1. Inspect the camshaft bushing and bores for signs of excessive wear. 2. Measure the camshaft bushing and bores with a telescoping bore gauge and micrometer. If out of specification, See: Removal and Replacement/Camshaft - Removal . 3. Inspect the camshaft bushing (1) oil holes for alignment with cylinder block. Camshaft Gear Inspect the camshaft gear for cracks (gear and hub), and chipped/broken/fretted teeth. If replacement is necessary, camshaft and gear are replaced as an assembly. See: Removal and Replacement/Camshaft - Removal . Thrust Plate Inspect the camshaft thrust plate for excessive wear in the camshaft contact area. Measure thrust plate thickness using the CAMSHAFT THRUST PLATE THICKNESS CHART. Replace any thrust plate that falls outside of these specifications: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2951 Camshaft: Removal and Replacement Camshaft - Removal CAMSHAFT 1. Disconnect both battery negative cables. 2. Recover A/C refrigerant (if A/C equipped). See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery 3. Raise vehicle on hoist. 4. Drain engine coolant into container suitable for re-use. See: Cooling System/Service and Repair 5. Lower vehicle. 6. Remove radiator upper hose. 7. Remove viscous fan/drive/shroud assembly. See: Cooling System/Radiator Cooling Fan/Service and Repair/Removal and Replacement/Radiator Fan - Removal 8. Disconnect the coolant recovery bottle hose from the radiator filler neck. 9. Disconnect lower radiator hose from radiator outlet. 10. Automatic Transmission models: Disconnect transmission oil cooler lines from front of radiator using Special Tool 6931 (unless equipped with finger-release disconnect). 11. Remove radiator mounting screws and lift radiator out of engine compartment. 12. Remove upper radiator support panel. 13. If A/C equipped, disconnect A/C condenser refrigerant lines. 14. Disconnect charge air cooler piping from the cooler inlet and outlet. 15. Remove the two charge air cooler mounting bolts. 16. Remove charge air cooler (and A/C condenser if equipped) from vehicle. 17. Remove accessory drive belt. See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Removal 18. Remove accessory drive belt tensioner. 19. Remove the fan support/hub assembly. 20. Remove crankshaft damper. See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Removal and Replacement/Vibration Damper - Removal 21. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the sealing surfaces. Remove dust seal with cover. 22. Using Special Tool 7471-B Crankshaft Barring Tool, rotate the crankshaft to align the timing marks on the crankshaft and the camshaft gears. 23. Remove the cylinder head cover. See: Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Removal 24. Remove the rocker arms, cross heads, and push rods. Mark each component so they can be installed in their original positions. NOTE: The # 5 cylinder intake and the # 6 cylinder intake and exhaust pushrods are removed by lifting them up and through the provided cowl panel access holes. Remove the rubber plugs to expose these relief holes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2952 25. Raise the tappets as follows, using the wooden dowel rods provided with the Miller Tool Kit 8502. a. Insert the slotted end of the dowel rod into the tappet. The dowel rods for the rear two cylinders will have to be cut for cowl panel clearance. Press firmly to ensure that it is seated in the tappet. b. Raise the dowel rod to bring the tappet to the top of its travel, and wrap a rubber band around the dowel rods to prevent the tappets from dropping into the crankcase. c. Repeat this procedure for the remaining cylinders. 26. Verify that the camshaft timing marks are aligned with the crankshaft mark. 27. Remove the bolts from the thrust plate. 28. Remove engine mount through bolts. 29. Install engine support fixture special tool # 8534, and steel bracket/wing nut special tool # 8534A. 30. Raise engine enough to allow camshaft removal. 31. Remove the camshaft, gear and thrust plate. Camshaft - Installation CAMSHAFT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2953 1. Lubricate the camshaft bushing and bores with fresh engine oil or suitable equivalent. 2. Liberally coat the camshaft lobes, journals, and thrust washer with fresh engine oil or suitable equivalent. CAUTION: When installing the camshaft, DO NOT push it in farther than it will go with the thrust washer in place. 3. Install the camshaft and thrust plate. Align the timing marks as shown. 4. Install the thrust plate bolts and tighten to 24 Nm (18 ft. lbs.) torque. 5. Measure camshaft back lash and end clearance. 6. Remove the wooden dowel rods and rubber bands from the tappets. 7. Lubricate the push rods with engine oil and install in their original location. Verify that they are seated in the tappets. 8. Lubricate the valve tips with engine oil and install the crossheads in their original locations. 9. Lubricate the crossheads and push rod sockets with engine oil and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 10. Verify valve lash adjustment See: Cylinder Head Assembly/Valve/Service and Repair/Procedures 11. Install the cylinder head cover. See: Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover Installation 12. Install gear housing cover. 13. Install the crankshaft damper. See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Removal and Replacement/Vibration Damper - Installation 14. Install the fan support/hub assembly. 15. Install the power steering pump. 16. Install accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.). 17. Install the accessory drive belt. See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Installation 18. Install the charge air cooler (with a/c condenser and auxiliary transmission oil cooler, if equipped) and tighten the mounting bolts to 2 Nm (17 in. lbs.) torque. 19. Connect charge air cooler inlet and outlet pipes. Tighten clamps to 11 Nm (95 in. lbs.) torque. 20. Install the radiator upper support panel. 21. Close radiator petcock and lower the radiator into the engine compartment. Tighten the mounting bolts to 11 Nm (95 in. lbs.) torque. 22. Raise vehicle on hoist. 23. Connect radiator lower hose and install clamp. 24. Connect transmission auxiliary oil cooler lines (if equipped). 25. Lower vehicle. 26. Install the fan drive/shroud assembly. 27. Install the coolant recovery and windshield washer fluid reservoirs to the fan shroud. 28. Connect the coolant recovery hose to the radiator filler neck. 29. Add engine coolant. See: Cooling System/Service and Repair 30. Charge A/C system with refrigerant (if A/C equipped). See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge 31. Connect the battery negative cables. 32. Start engine and check for engine oil and coolant leaks. Camshaft Bearings - Removal Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2954 CAMSHAFT BEARINGS NOTE: Measure the diameter of each bore. If the camshaft bore for the cam bushing is worn beyond the limit, install a new service bushing. Inspect the rest of the camshaft bores for damage or excessive wear.If the bores without a bushing are worn beyond the limit, the engine must be removed for machining and installation of service bushings. If badly worn, replace the cylinder block. 1. Remove the camshaft See: Camshaft - Removal . 2. Remove the bushing from the No.1 bore. 3. Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing. Camshaft Bearings - Installation CAMSHAFT BEARINGS 1. Apply a coating of Loctite(R) 640 Adhesive to the backside of the new bushing. Avoid getting adhesive in the oil hole. 2. Use a universal cam bushing installation tool and install the front bushing (1) so that it is even with the front face of the cylinder block. The oil hole must be aligned. A 3.2 mm (0.128 inch) diameter rod must be able to pass through the hole. 3. Measure the installed bushings at the front bore. The minimum inside diameter is 54.083 mm (2.1293 inch), and the maximum inside diameter is is 54.147 mm. (2.1318 in.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures Lifter / Lash Adjuster: Procedures Cleaning CLEANING Clean tappet with a suitable solvent. Rinse in hot water and blow dry with a clean shop rag or compressed air. Inspection INSPECTION 1. Visually inspect the tappet the tappet socket, stem, and face for excessive wear, cracks, or obvious damage. 2. Measure the tappet stem diameter. Replace the tappet if it falls below the minimum size. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 2959 Lifter / Lash Adjuster: Removal and Replacement Valve Tappet(s) - Removal REMOVAL NOTE: This procedure requires use of Miller Tool 8502 Tappet Replacement Kit. 1. Remove camshaft See: Camshaft/Service and Repair/Removal and Replacement/Camshaft Removal . 2. Insert the trough (1) (provided with tool kit) the full length of the camshaft bore. Make sure the cap end goes in first and the open side faces up (towards tappets). 3. Remove only one tappet at a time. Remove rubber band from one cylinder pair and attach tappet dowel not being removed to the next cylinder pair. 4. Raise dowel rod (disengage from tappet) and allow tappet to fall into trough. 5. Carefully remove trough (do not rotate) and tappet. If the tappet is not being replaced, mark it so it can be installed in its original location. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 2960 6. Re-install trough (1) and repeat procedure on remaining tappets. Valve Tappet(s) - Installation INSTALLATION 1. Insert the trough (1) the full length of the camshaft bore. Again, make sure the cap end goes in first and the open side faces up (towards tappets). 2. Lower the tappet installation tool through the push rod hole and into the trough. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 2961 3. Retrieve the tappet installation tool using the hooked rod provided with the tool kit. 4. Lubricate the tappet with clean engine oil or suitable equivalent and install the tappet to the installation tool. 5. Pull the tappet up and into position. If difficulty is experienced getting the tappet to make the turn into the tappet bore, wiggle the trough while gently pulling up on the tappet. 6. With the tappet in place, rotate the trough one half turn so the open side is down (toward crankshaft). 7. Remove the tappet installation tool from the tappet. 8. Re-install a dowel rod and secure the rod with a rubber band. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 2962 9. Rotate the trough one half turn and repeat the procedure for the remaining tappets. 10. Install the camshaft See: Camshaft/Service and Repair/Removal and Replacement/Camshaft Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by passages intersecting the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves. The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Cleaning CLEANING Clean all components in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with compressed air. Inspect oil passages in rocker arms and pedestals. Apply compressed air to lubrication orifices to purge contaminants. Inspection INSPECTION Rocker Arms 1. Remove rocker shaft and inspect for cracks and excessive wear in the bore or shaft. Remove socket and inspect ball insert and socket for signs of wear. Replace retainer if necessary. Measure the rocker arm bore and shaft. Push Rods Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2968 Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube. Roll the push rod on a flat work surface with the socket end hanging off the edge. Replace any push rod that appears to be bent. Crossheads Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2969 Rocker Arm Assembly: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove cylinder head cover See: Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover Removal . 3. Remove the rocker arm/pedestal fasteners and remove rocker arm (1) and pedestal (2) from cylinder head. Mark the arms and pedestals so they can be installed in their original position. CAUTION: When removing the rocker arms, the sockets may come loose and fall into the engine. Make sure they stay with the arm upon removal/installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 2970 4. Lift the push rod(s) up and out of the engine. Mark them so they can be installed in their original position. NOTE: The # 5 cylinder intake and exhaust, and # 6 cylinder intake and exhaust push rods must be raised through the provided cowl panel access holes. 5. Lift the crossheads off of the valve stems. Mark them so they can be installed in their original position. Installation INSTALLATION 1. If previously removed, install the push rods in their original location. Verify that they are seated in the tappets. 2. Lubricate the valve tips and install the crossheads in their original locations. 3. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 4. Verify valve lash adjustment See: Cylinder Head Assembly/Valve/Service and Repair/Procedures . 5. Install cylinder head cover. See: Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover Installation 6. Connect battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Cap Step 1 .................................................................................................................................................. .................................................. 30 Nm (22 Ft.Lb.) Step 2 .................................................................. .................................................................................................................................. 60 Nm (44 Ft.Lb.) Step 3 ....................................................................................................................................... ............................................................. Rotate 60 Degrees Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2975 Connecting Rod Bearing: Service and Repair CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE 1. Measure the connecting rod bore with bearings removed and the bolts tightened to 100 Nm (73 ft. lbs.) torque. 2. Measure the connecting rod bore with the bearings installed and the bolts tightened to 100 Nm (73 ft. lbs.) torque. Measure within 20° arc from each side of the parting line. Also measure 90° from parting line. Record the smallest and largest diameter. Measure the diameter of the rod journal at the location shown. Calculate the average diameter for each side of the journal. Determine minimum bearing clearance by calculating the differance between the smallest connecting rod bore diameter with the bearing installed and the average diameter for each side of the crankshaft journal. Determine the maximum bearing clearance by calculating the difference between the largest connecting rod bore diameter and the average diameter with the bearing installed for each side of the crankshaft journal. If the crankshaft is within limits, replace the bearing. If the crankshaft is out of limits, grind the crankshaft to the next smaller size and use oversize rod bearings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications SPECIFICATIONS - 6.7L DIESEL Piston Pins Connecting Rods Torque Specifications Connecting Rod Cap Step 1 .................................................................................................................................................. .................................................. 30 Nm (22 Ft.Lb.) Step 2 .................................................................. .................................................................................................................................. 60 Nm (44 Ft.Lb.) Step 3 ....................................................................................................................................... ............................................................. Rotate 60 Degrees Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2979 Connecting Rod: Description and Operation DESCRIPTION PISTONS The piston is constructed of aluminum and is gravity cast, free floating design. The piston incorporates a centrally located high swirl combustion bowl, and utilizes a "keystone" style top compression ring, and a "Tapered Face" intermediate ring, for superior cylinder wall scraping. Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals. All pistons are gallery cooled and utilize J-jet piston cooling nozzles. Pistons are directional in order to provide clearance to piston cooling nozzles. CONNECTING RODS The connecting rods are a split angle design. They have a pressed-in-place wrist pin bushing that is lubricated by piston cooling nozzle oil spray. Machined connecting rods are no longer used in the diesel engine. Do not install machined connecting rods into an engine that has fractured split connecting rods. Fractured split connecting rods are first manufactured as a single piece and then fractured into two pieces. Fractured split connecting rods can be identified by a rough and irregular surface at the connecting rod split face. To properly assemble the rod cap to the connecting rod, the bearing tangs on the connecting rod and cap must be located on the same side of the rod. The long end of the connecting rod must be assembled on the intake or camshaft side of the engine. Each matched fractured split connecting rod and cap is an assembly and are not interchangeable. If a connecting rod or cap is damaged, the entire assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures Connecting Rod: Procedures Piston and Connecting Rod - Cleaning CLEANING CAUTION: DO NOT use bead blast to clean the pistons. DO NOT clean the pistons and rods in an acid tank. PISTON Clean the pistons and pins in a suitable solvent, rinse in hot water and blow dry with compressed air. Soaking the pistons over night will loosen most of the carbon build up. De-carbon the ring grooves with a broken piston ring and again clean the pistons in solvent. Rinse in hot water and blow dry with compressed air. CONNECTING ROD Clean the connecting rods in a suitable solvent, rinse in hot water and blow dry with compressed air. Piston and Connecting Rod - Inspection CONNECTING ROD Inspect the connecting rod for damage and wear. The I-Beam section of the connecting rod cannot have dents or other damage. Damage to this part can cause stress risers which will progress to breakage. Measure the connecting rod pin bore (1). The maximum diameter is 40.042 mm (1.5765 inch), minimum diameter is 40.019 mm (1.5756 inch). If out of limits, replace the connecting rod. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2982 Connecting Rod: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Disconnect the battery cables. 2. Remove the cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal . 3. Remove the oil pan and suction tube See: Engine Lubrication/Oil Pan/Service and Repair/Removal and Replacement/Engine Oil Pan - Removal . 4. Remove bolts and the block stiffener. 5. Using Miller Tool 7471-B crankshaft barring tool, rotate the crankshaft so all of the pistons are below TDC. 6. Before removing the piston(s) from the bore(s): a. Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush. b. If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove more metal than necessary to remove the ridge. 7. Remove the J-jet cooling nozzles. NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring. 8. Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197 in.) of the piston diameter. DO NOT stamp over the piston pin. 9. Mark the connecting rod and cap with the corresponding cylinder numbers. 10. Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not damaged. 11. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore. 12. Store the piston/rod assemblies in a rack. Piston and Connecting Rod - Installation INSTALLATION 1. Lubricate the cylinder bores with clean engine oil. 2. Generously lubricate the rings and piston skirts with clean engine oil. 3. Orientate the rings on the piston See: Piston Ring/Service and Repair . 4. Compress the rings using a piston ring compressor tool (1). If using a strap-type ring compressor, make sure the inside end of the strap does not hook on a ring gap and break the ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2983 5. Bar the crankshaft so the rod journal for the piston to be installed is at BDC (Bottom Dead Center). 6. Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the connecting rod is oriented properly. 7. Position the piston and rod assembly into the cylinder bore with the front of the piston oriented properly according to the stamping in the top of the piston. Use care when you install the piston and connecting rod so the cylinder bore is not damaged. The long side of the connecting rod must be installed on the exhaust side of the engine. 8. Push the piston into the bore until the top of the piston is approximately 50 mm (2 inch) below the top of the block. Carefully pull the connecting rod onto the crankshaft journal. 9. Use clean engine oil to lubricate the threads and under the heads of the connecting rod bolts. 10. For fractured/split type connecting rods, the long end of the rod must be installed away from the intake side of the engine. a. The connecting rod split/face must face toward the same side as the piston notch feature on the skirt. The split face will face toward the exhaust side of the engine if properly installed. 11. Install the rod cap and bolts to the connecting rod. Tighten the connecting rod bolts evenly in 3 steps. - Tighten the bolts to 30 Nm (22 ft. lbs.) torque. - Tighten the bolts to 60 Nm (44 ft. lbs.) torque. - Rotate 60° clockwise. 12. The crankshaft must rotate freely. Check for freedom of rotation as the caps are installed. If the crankshaft does not rotate freely, check the installation of the rod bearing and the bearing size. 13. Measure the side clearance between the connecting rod and the crankshaft. DO NOT measure the clearance between the cap and crankshaft. 14. Install J-jet piston cooling nozzles. 15. Install block stiffener. Torque to 43 Nm (32 ft. lbs.). 16. Install the suction tube and oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Removal and Replacement/Engine Oil Pan - Installation . 17. Install the cylinder head onto the engine See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head Installation . 18. Install a new filter and fill the crankcase with new engine oil.Prefill the filter with clean oil. 19. Connect the battery negative cables and start engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Damper Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications SPECIFICATIONS - 6.7L DIESEL CAUTION: The 5.9L and 6.7L engine has different torque procedures for new and previously installed main bearing capscrews. Failure to use the correct torque procedure can result in engine damage. Main Bearing Cap-Bolts (Previously Used) Step 1 .................................................................................................................................................. .................................................. 60 Nm (44 Ft.Lb.) Step 2 .................................................................. .................................................................................................................................. 80 Nm (59 Ft.Lb.) Step 3 ....................................................................................................................................... ............................................................. Rotate 90 Degrees Main Bearing Cap-Bolts (New) Step 1 .................................................................................................................................................. ................................................ 120 Nm (89 Ft.Lb.) Step 2 .................................................................. ................................................................................................................................ Loosen Completely Step 3 ............................................................................................................................... ..................................................................... 60 Nm (44 Ft.Lb.) Step 4 ............................................... ..................................................................................................................................................... 85 Nm (63 Ft.Lb.) Step 5 .......................................................................................................................... ........................................................................ Rotate 120 Degrees Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2990 Crankshaft Main Bearing: Service and Repair MAIN BEARING CLEARANCE Inspect the main bearing bores for damage or abnormal wear. 1. Remove bearings and measure main bearing bore diameter after torquing main bearing cap bolts to 176 Nm (130 ft. lbs.). 2. Install the crankshaft main bearings and measure main bearing bore diameter with the main bolts tightened to 176 Nm (130 ft. lbs.) torque. 3. Measure the diameter of the main journal at the locations shown. Calculate the average diameter for each side of the journal. 4. Calculate the main bearing journal to bearing clearance. Maximum clearance is 0.119 mm (0.00475 inch). If the crankshaft journal is within limits, replace the main bearings. If not within specifications, grind the crankshaft to next size and use oversize bearings. 5. Measure thrust distance at the No.6 position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Removal REMOVAL 1. Disconnect the battery negative cables. 2. Raise vehicle on hoist. 3. Remove the oil pan drain plug and drain the engine oil. Re-install plug and torque to 50 Nm (44 ft. lbs.) torque. 4. Remove transmission and transfer case (if equipped) from vehicle. 5. Remove flywheel or torque converter drive plate. 6. Remove flywheel adapter plate. 7. Disconnect starter cables from starter motor. 8. Remove starter motor and transmission adapter plate assembly. 9. Remove four 4 oil pan rear bolts. Slide a feeler gauge between the seal retainer and oil pan gasket to break the seal. 10. Remove the six 6 retainer-to-block bolts (3). 11. Remove the rear seal retainer, and gasket (2). 12. Support the seal retainer and drive out the crankshaft seal with a hammer and suitable punch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal > Page 2995 Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Installation INSTALLATION 1. If using the old seal retainer, the crankshaft seal must be replaced. 2. Inspect oil pan gasket for nicks or cuts. If gasket is damaged, the oil pan must be removed and gasket must be replaced. Wipe oil pan gasket dry and apply light coating of RTV. 3. Using the retainer alignment/seal installation tool provided in the seal service kit, install the alignment tool into the retainer and install to the cylinder block, using a new gasket. Tighten the six (6) mounting bolts by hand. 4. The seal alignment tool is used to align rear cover properly. Starting with the center two bolts, tighten the retainer in a circular pattern to 10 Nm (89 in. lbs.). Remove the alignment tool. CAUTION: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. The crankshaft and seal surfaces must be completely dry when the seal is installed. Use a soap and water solution on outside diameter of seal to ease assembly. 5. Make sure the provided seal pilot (1) is installed into the new crankshaft seal (3). Use the alignment/installation tool and press the seal onto the crankshaft. Alternately drive the seal at the 12, 3, 6 and 9 o'clock positions. 6. Remove the alignment tool and trim the retainer gasket (1) even with the oil pan mounting surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal > Page 2996 7. Remove the seal pilot. 8. Apply a small amount of Mopar(R) Silicone Rubber Adhesive Sealant to the oil pan rail T-joints. 9. Install the four (4) oil pan rear mounting bolts and torque to 28 Nm (21 ft. lbs.). 10. Install new rectangular ring seal for cam bore. 11. Install the flywheel housing and bolts. Torque bolts to 77 Nm (57 ft. lbs.). 12. Install the flywheel housing and bolts. Torque bolts to 77 Nm (57 ft. lbs.). NOTE: A new clamping ring must be used on early or late builds, automatic or manual. Do not reuse clamping ring. 13. Install the dual mass flywheel with crankshaft adapter. Tighten bolts to 137 Nm (101 ft. lbs.). 14. Install the starter motor. 15. Install the transmission and transfer case (if equipped). 16. Lower vehicle. 17. Fill the crankcase with new engine oil. 18. Connect the battery negative cables. 19. Start engine and check for oil leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications SPECIFICATIONS - 6.7L DIESEL CAUTION: The 5.9L and 6.7L engine has different torque procedures for new and previously installed main bearing capscrews. Failure to use the correct torque procedure can result in engine damage. Main Bearing Cap-Bolts (Previously Used) Step 1 .................................................................................................................................................. .................................................. 60 Nm (44 Ft.Lb.) Step 2 .................................................................. .................................................................................................................................. 80 Nm (59 Ft.Lb.) Step 3 ....................................................................................................................................... ............................................................. Rotate 90 Degrees Main Bearing Cap-Bolts (New) Step 1 .................................................................................................................................................. ................................................ 120 Nm (89 Ft.Lb.) Step 2 .................................................................. ................................................................................................................................ Loosen Completely Step 3 ............................................................................................................................... ..................................................................... 60 Nm (44 Ft.Lb.) Step 4 ............................................... ..................................................................................................................................................... 85 Nm (63 Ft.Lb.) Step 5 .......................................................................................................................... ........................................................................ Rotate 120 Degrees Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 3000 Crankshaft: Description and Operation DESCRIPTION The crankshaft is a forged steel, internally balanced unit. It is supported by seven main bearings, with position number six designated as the thrust journal. The crankshaft is held in place by main caps and 12 mm capscrews. The crankshaft also has internal cross drillings to supply the connecting rods with engine oil. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Gear - Installation Crankshaft: Service and Repair Crankshaft Gear - Installation INSTALLATION - GEAR 1. Remove all burrs and make sure the gear surface on the end of the crankshaft is smooth. 2. If removed, install a new alignment pin. Drive the pin in using a ball- peen hammer, leaving it protruding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch) above the crankshaft. WARNING: WEAR PROTECTIVE GLOVES TO PREVENT INJURY. CAUTION: DO NOT heat the gear longer than 45 minutes. 3. Heat the crankshaft gear for 45 minutes at a temperature of 149°C (300°F). Do not use torch, gear failure will occur. 4. Apply a thin coat of lubricant to the nose of the crankshaft. 5. Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the gear contacts the shoulder. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description Engine Block Heater: Description and Operation Engine Block Heater - Description DESCRIPTION WARNING: Do not operate engine unless block heater cord has been disconnected from power source and secured in place. The power cord must be secured in its retaining clips and routed away from exhaust manifolds and moving parts. An optional engine block heater is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. The 3.7L/4.7L gas powered engines have the block heater located to the rear on the right side of the engine. The diesel engine has the block heater located on the right side of the engine below the exhaust manifold next to the oil cooler (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description > Page 3007 The 5.7L engine has the block heater (1) located on the left side of the engine below the exhaust manifold in the rear of the engine and is not immersed in engine coolant but makes direct contact with the block. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description > Page 3008 Engine Block Heater: Description and Operation Engine Block Heater - Operation OPERATION The heater warms the engine coolant providing easier engine starting and faster warm-up in low temperatures. Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded three wire extension cord provides the electricity needed to heat the element. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 3009 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER If the unit does not operate, possible causes can be either the power cord or the heater element. Test the power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heater element continuity with an ohmmeter or a 12-volt test light. CAUTION: To prevent damage, the power cord must be secured in it's retainer clips and away from any components that may cause abrasion or damage, such as linkages, exhaust components, etc. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal Engine Block Heater: Service and Repair Engine Block Heater - Removal 6.7L DIESEL 1. Disconnect the battery negative cables. 2. Drain coolant from radiator and cylinder block See: Cooling System/Service and Repair . 3. Unscrew the power cord retaining cap and disconnect cord from heater element. 4. Using a suitable size socket, loosen and remove the block heater element. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal > Page 3012 Engine Block Heater: Service and Repair Engine Block Heater - Installation 6.7L DIESEL 1. Clean and inspect the threads in the cylinder block and heater element. 2. Coat heater element threads with Mopar(R) Thread Sealer with Teflon. 3. Screw block heater (1) into cylinder block and tighten to 75 Nm (55 ft. lbs.). 4. Connect block heater cord and tighten retaining cap. 5. Fill cooling system with recommended coolant See: Cooling System/Service and Repair . 6. Start and warm the engine. 7. Check block heater for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Damper Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Procedures Harmonic Balancer - Crankshaft Pulley: Procedures INSPECTION NOTE: The Crankshaft damper is of viscous design and the speed indicator is incorporated into the crankshaft damper. 1. Inspect the damper hub for cracks and replace if any are found. 2. If the crankshaft damper is leaking fluid, discard and replace the crankshaft damper. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Procedures > Page 3018 Harmonic Balancer - Crankshaft Pulley: Removal and Replacement Vibration Damper - Removal REMOVAL 1. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Removal . 2. Remove the four (4) damper to crankshaft bolts and remove damper. Vibration Damper - Installation INSTALLATION 1. Install the crankshaft damper and bolts. Tighten bolts to 40 Nm (30 ft. lbs.) torque, plus an additional 60°. NOTE: The damper must be installed so the hole is located over the dowel pin. 2. Install the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Specifications Pistons Piston Pins Piston Rings Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 3022 Piston: Description and Operation DESCRIPTION PISTONS The piston is constructed of aluminum and is gravity cast, free floating design. The piston incorporates a centrally located high swirl combustion bowl, and utilizes a "keystone" style top compression ring, and a "Tapered Face" intermediate ring, for superior cylinder wall scraping. Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals. All pistons are gallery cooled and utilize J-jet piston cooling nozzles. Pistons are directional in order to provide clearance to piston cooling nozzles. CONNECTING RODS The connecting rods are a split angle design. They have a pressed-in-place wrist pin bushing that is lubricated by piston cooling nozzle oil spray. Machined connecting rods are no longer used in the diesel engine. Do not install machined connecting rods into an engine that has fractured split connecting rods. Fractured split connecting rods are first manufactured as a single piece and then fractured into two pieces. Fractured split connecting rods can be identified by a rough and irregular surface at the connecting rod split face. To properly assemble the rod cap to the connecting rod, the bearing tangs on the connecting rod and cap must be located on the same side of the rod. The long end of the connecting rod must be assembled on the intake or camshaft side of the engine. Each matched fractured split connecting rod and cap is an assembly and are not interchangeable. If a connecting rod or cap is damaged, the entire assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Head Gasket Selection HEAD GASKET SELECTION 1. Measure piston protrusion for all six pistons. 2. Calculate the average piston protrusion. Maximum allowable protrusion is 0.516 mm (0.020 inch). NOTE: There is only one head gasket available for the 6.7L engine. Piston and Connecting Rod - Inspection PISTONS Inspect the pistons for damage and excessive wear. Check top of the piston, ring grooves, skirt and pin bore. Measure the piston skirt diameter. If the piston is out of limits, replace the piston. The upper groove only needs to be inspected for damage. Use a new piston ring (2) to measure the clearance in the intermediate ring groove. Minimum clearance is 0.045 mm (0.0018 inch), maximum clearance is 0.095 mm (.0037 inch). If the clearance of the intermediate ring exceeds specifications, replace the piston (3). Use a new oil ring to measure the clearance in the oil groove. Minimum clearance is 0.040 mm (0.0016 inch), maximum clearance is 0.085 mm (.0033 inch). If the clearance exceeds specifications, replace the piston. Measure the pin bore (2). The maximum diameter is 40.012 mm (1.5753 inch), Minimum is 40.006 mm (1.575 inch). If the bore is over limits, replace the piston (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 3025 Inspect the piston pin for nicks, gouges and excessive wear. Measure the pin diameter (1). The minimum diameter is 39.990 mm (1.5744 inch), maximum 40.003 mm (1.5749 inch). If the diameter is out of limits, replace the pin (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 3026 Piston: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Disconnect the battery cables. 2. Remove the cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal . 3. Remove the oil pan and suction tube See: Engine Lubrication/Oil Pan/Service and Repair/Removal and Replacement/Engine Oil Pan - Removal . 4. Remove bolts and the block stiffener. 5. Using Miller Tool 7471-B crankshaft barring tool, rotate the crankshaft so all of the pistons are below TDC. 6. Before removing the piston(s) from the bore(s): a. Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush. b. If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove more metal than necessary to remove the ridge. 7. Remove the J-jet cooling nozzles. NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring. 8. Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197 in.) of the piston diameter. DO NOT stamp over the piston pin. 9. Mark the connecting rod and cap with the corresponding cylinder numbers. 10. Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not damaged. 11. Use a hammer handle or similar object to push the piston and connecting rod through the cylinder bore. 12. Store the piston/rod assemblies in a rack. Piston and Connecting Rod - Installation INSTALLATION 1. Lubricate the cylinder bores with clean engine oil. 2. Generously lubricate the rings and piston skirts with clean engine oil. 3. Orientate the rings on the piston See: Piston Ring/Service and Repair . 4. Compress the rings using a piston ring compressor tool (1). If using a strap-type ring compressor, make sure the inside end of the strap does not hook on a ring gap and break the ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 3027 5. Bar the crankshaft so the rod journal for the piston to be installed is at BDC (Bottom Dead Center). 6. Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the connecting rod is oriented properly. 7. Position the piston and rod assembly into the cylinder bore with the front of the piston oriented properly according to the stamping in the top of the piston. Use care when you install the piston and connecting rod so the cylinder bore is not damaged. The long side of the connecting rod must be installed on the exhaust side of the engine. 8. Push the piston into the bore until the top of the piston is approximately 50 mm (2 inch) below the top of the block. Carefully pull the connecting rod onto the crankshaft journal. 9. Use clean engine oil to lubricate the threads and under the heads of the connecting rod bolts. 10. For fractured/split type connecting rods, the long end of the rod must be installed away from the intake side of the engine. a. The connecting rod split/face must face toward the same side as the piston notch feature on the skirt. The split face will face toward the exhaust side of the engine if properly installed. 11. Install the rod cap and bolts to the connecting rod. Tighten the connecting rod bolts evenly in 3 steps. - Tighten the bolts to 30 Nm (22 ft. lbs.) torque. - Tighten the bolts to 60 Nm (44 ft. lbs.) torque. - Rotate 60° clockwise. 12. The crankshaft must rotate freely. Check for freedom of rotation as the caps are installed. If the crankshaft does not rotate freely, check the installation of the rod bearing and the bearing size. 13. Measure the side clearance between the connecting rod and the crankshaft. DO NOT measure the clearance between the cap and crankshaft. 14. Install J-jet piston cooling nozzles. 15. Install block stiffener. Torque to 43 Nm (32 ft. lbs.). 16. Install the suction tube and oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Removal and Replacement/Engine Oil Pan - Installation . 17. Install the cylinder head onto the engine See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head Installation . 18. Install a new filter and fill the crankcase with new engine oil.Prefill the filter with clean oil. 19. Connect the battery negative cables and start engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Specifications Pistons Piston Pins Piston Rings Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 3031 Piston Ring: Service and Repair PISTON RING FITTING 1. Determine the piston diameter and obtain the appropriate ring set. The piston rings can be identified as shown. 2. Position each ring in the cylinder and use a piston (1) to square it with the bore at a depth (3) of 89.0 mm (3.5 inch). 3. Use a feeler gauge to measure the piston ring gap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 3032 4. The top surface of all of the compression rings are identified with the word TOP or the supplier's MARK. Assemble the rings with the word TOP or the supplier's MARK up. 5. Position the oil ring expander (2) in the oil control ring (1) groove (bottom groove). NOTE: There is no (TOP) mark on the oil ring. 6. Install the oil control ring (1) with the end gap OPPOSITE the ends on the expander. 7. Install the intermediate piston ring in the second groove. 8. Install the top piston ring in the top groove. 9. Position the rings as shown. - Install top and second compression rings on piston with ring gaps 180° apart. - Install oil control ring with ring gap 90° from top and second ring. Do not position gaps over wrist pin hole. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60° C (140° F). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover See: Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Removal . 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjustment/resettingis not necessary. If measurement finds the lash outside of the limits, adjustment/resettingis required. 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. 7. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments > Page 3037 method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits. 8. Install the cylinder head cover See: Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Installation . 9. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Description and Operation Rocker Arm Assembly: Description and Operation DESCRIPTION The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by passages intersecting the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves. The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Cleaning CLEANING Clean all components in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with compressed air. Inspect oil passages in rocker arms and pedestals. Apply compressed air to lubrication orifices to purge contaminants. Inspection INSPECTION Rocker Arms 1. Remove rocker shaft and inspect for cracks and excessive wear in the bore or shaft. Remove socket and inspect ball insert and socket for signs of wear. Replace retainer if necessary. Measure the rocker arm bore and shaft. Push Rods Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 3043 Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube. Roll the push rod on a flat work surface with the socket end hanging off the edge. Replace any push rod that appears to be bent. Crossheads Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 3044 Rocker Arm Assembly: Removal and Replacement Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove cylinder head cover See: Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Removal . 3. Remove the rocker arm/pedestal fasteners and remove rocker arm (1) and pedestal (2) from cylinder head. Mark the arms and pedestals so they can be installed in their original position. CAUTION: When removing the rocker arms, the sockets may come loose and fall into the engine. Make sure they stay with the arm upon removal/installation. 4. Lift the push rod(s) up and out of the engine. Mark them so they can be installed in their original position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 3045 NOTE: The # 5 cylinder intake and exhaust, and # 6 cylinder intake and exhaust push rods must be raised through the provided cowl panel access holes. 5. Lift the crossheads off of the valve stems. Mark them so they can be installed in their original position. Installation INSTALLATION 1. If previously removed, install the push rods in their original location. Verify that they are seated in the tappets. 2. Lubricate the valve tips and install the crossheads in their original locations. 3. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 4. Verify valve lash adjustment See: Valve/Service and Repair/Procedures . 5. Install cylinder head cover. See: Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover Installation 6. Connect battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures Valve Cover: Procedures Cleaning CLEANING Using a suitable solvent, Clean and dry gasket mating surfaces on cylinder head and rocker housing. Wipe gasket dry and inspect for re-use. Inspection INSPECTION The cylinder head cover gasket and rocker housing gasket, are reusable. However, should cracks, nicks, or tears be present in the rubber/silicone construction, the defective components should be replaced. Also replace gasket if it is no longer flexible. Inspect cylinder head cover rubber isolated capscrews for cracks, nicks, or tears.Do not reuse gasket if it has been removed from the groove in the rocker housing or cylinder head cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 3050 Valve Cover: Removal and Replacement Rocker Housing ROCKER HOUSING 1. Remove the breather cover and the cylinder head cover. See: Cylinder Head Cover - Installation 2. Remove injector harness nuts from injectors. 3. Remove cylinder head cover gasket. See: Cylinder Head Cover - Installation 4. Remove rocker housing bolts. 5. Remove rocker housing and gasket. Cylinder Head Cover CYLINDER HEAD COVER 1. Disconnect both negative battery cables. See: Starting and Charging/Battery/Battery Cable/Service and Repair/Battery Cables - Removal 2. Remove the Breather Cover Capscrews (8-M6 screws). 3. Remove the CCV breather and filter cover (3). 4. Disconnect CCV Tube (4) at the CDR valve (one spring clamp) and remove 10mm nut from tube bracket at EGR Cooler support bracket stud. 5. Disconnect CDR valve Tube to Air Inlet Silencer (Spring Clamp). 6. Disconnect CDR/Valve cover pressure sensor connector. 7. Remove Oil fill cap. 8. Remove CCV oil drains (2) from valve cover (2 hoses). 9. Disconnect both injector harness connectors (1). 10. Remove six (6) valve cover capscrews (10mm). 11. Remove the valve cover. 12. Loosen injector wire nuts from the valve cover gasket (8mm) 13. Remove gasket. Cylinder Head Cover Gasket CYLINDER HEAD COVER GASKET Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 3051 1. Remove cylinder head cover. 2. Disconnect injector harness connectors (3) at cylinder head cover gasket. 3. Remove injector solenoid nuts (1) at injectors. 4. Remove cylinder head cover gasket (2). Rocker Housing ROCKER HOUSING 1. Inspect rocker housing gasket for cuts, nicks, or tears. Replace if damaged or if gasket has come out of groove. 2. Inspect rocker housing gasket for proper installation in groove. Gasket bead must be centered in groove. A gasket bead that is tilted to the side will cause an oil leak. CAUTION: When installing rocker housing onto cylinder head, do not slide housing from side to side, The gasket could fall out or be damaged. 3. Install the rocker housing. Carefully guide the rocker housing evenly down onto the cylinder head. 4. Install rocker housing bolts and tighten finger tight. 5. Torque bolts, working from center out, to 24 Nm (18 ft. lbs.). Cylinder Head Cover CYLINDER HEAD COVER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 3052 NOTE: Gasket must be completely dry and free of oil before installation. 1. Wipe oil from the valve cover gasket, rocker box, and valve cover. 2. Inspect valve cover gasket for tears, or splits. Replace if necessary. 3. Install the valve cover gasket on the rocker box. 4. Install the injector nuts (8 mm) to injector studs. Torque to 1.25 Nm (11 in. lbs.). 5. Install valve cover and valve cover capscrews (10mm). tighten from center out. Torque to 24 Nm (18 ft. lbs.). 6. Install the valve cover CCV drain hoses (2). 7. Remove any oil from the CCV seal area and install the CCV filter. 8. Install the CCV cover and capscrews (6mm). Torque to 10 Nm (89 in. lbs.). 9. Connect CDR valve tube to Air Inlet Silencer (spring clamps). 10. Connect the Breather/Valve Cover Pressure sensor. 11. Install oil fill cap. 12. Connect the batteries. 13. Start the vehicle and check for leaks. Cylinder Head Cover Gasket CYLINDER HEAD COVER GASKET Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Procedures > Page 3053 1. Clean oil from cylinder head cover gasket 2. Inspect cylinder head cover gasket for cuts or damage. Replace if damaged. 3. Place cylinder head cover gasket on top of rocker housing (2). 4. Install injector solenoid nuts (1) at injectors. Torque to 1.25 Nm ( 11 in. lbs. ). 5. Connect injector harness connectors (3) at cylinder head cover gasket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation Valve: Description and Operation DESCRIPTION The intake valves (1) are made of heat resistant steel, and have chrome plated stems to prevent scuffing. The exhaust valves are made of iron alloys (2). The intake and exhaust valves are both similar in head diameter and overall length, but they have unique face angles which makes them non-interchangeable. The valves are distinguished by unique dimples on the exhaust valve head (2). The exhaust valve springs are made from high strength, chrome silicon steel. The exhaust valve springs are also exhaust brake compatible. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures Valve: Procedures VALVES, GUIDES AND SPRINGS REMOVAL 1. Remove cylinder head See: Service and Repair/Removal and Replacement/Cylinder Head Removal . 2. Support cylinder head on stands, or install head bolts upside down (through combustion surface side) to protect injector tips from damage from work bench. 3. Install the valve spring compressor mounting base (1) as shown. 4. Install the compressor top plate, washer, and nut. Using a suitable wrench, tighten the nut (clockwise) to compress the valve springs and remove the locks. 5. Rotate the compressor nut counter-clockwise to relieve tension on the springs. Remove the spring compressor (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 3059 6. Remove the retainers (5), springs (4), valve seals (3) (if necessary), and valves (2). Arrange or number all components so they can be installed in their original locations. 7. Repeat the procedure on all cylinders to be serviced. CLEANING Clean the valve stems with crocus cloth or a Scotch-Brite(TM) pad. Remove carbon with a soft wire brush. Clean valves, springs, retainers, and valve retaining locks in a suitable solvent. Rinse in hot water and blow dry with compressed air. INSPECTION Visually inspect the valves for abnormal wear on the heads, stems, and tips. Replace any valve that is worn out or bent. Measure the valve stem diameter in three places as shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 3060 Measure the cylinder head valve guide bore. Measure valve margin (rim thickness). Measure the valve spring free length and maximum inclination. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 3061 Test valve spring force with tool C-647 (1). Specification 72.0 - 80.7 lbs. when compressed to 35.33 mm (1.39 in.). INSTALLATION 1. Install new valve seals. The yellow seals are for the intake valves and the green seals are for the exhaust valves. 2. Install the valves in their original position. The exhaust valves are identified by a dimple on the valve head. 3. Install the valve (2), springs (4), and retainer (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 3062 4. Install the valve spring compressor tool 8319-A (1)as shown. 5. Compress the valve springs and install the valve retaining locks. 6. Remove the compressor and repeat the procedure on the remaining cylinders. 7. Install new o-ring and sealing washer on injector. 8. Lubricate o-ring and injector bore. 9. Verify sealing washer (shim) was removed with old injector. 10. Install injector Refer to See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Fuel Injector - Installation . 11. Install the cylinder head See: Service and Repair/Removal and Replacement/Cylinder Head Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 3063 Valve: Removal and Replacement Removal - Valve Springs REMOVAL - VALVE SPRINGS 1. Disconnect the battery negative cables. 2. Remove the cylinder head cover See: Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Removal . 3. Disconnect the injector harness connectors at cylinder head cover gasket. Remove all injector solenoid nuts. Remove cylinder head cover gasket. 4. Remove injector(s) for cylinder(s) to be serviced. See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Fuel Injector - Removal or See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Fuel Injector - Removal . 5. Remove the rocker housing. 6. Remove the rocker arms and crossheads from the cylinder(s) to be serviced. Mark each component so they can be installed in their original position. 7. Using the crankshaft barring tool # 7471-B (2), rotate the engine to position the damper mark in the 12 o'clock position. At this engine position, cylinders #1 and #6 can be serviced. 8. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Removal . 9. With the damper TDC mark in the 12 o'clock position, add a paint mark anywhere on the gear housing cover next to the crankshaft damper. Place another mark on the vibration damper in alignment with the mark you just made on the cover. 10. Divide the crankshaft damper into three equally sized segments as follows: a. Using a tape measure, measure the circumference of the crankshaft damper and divide the measurement by three (3). b. Measure that distance in a counterclockwise direction from the first balancer mark and place another mark on the balancer. c. From the second damper mark, again measure in a counterclockwise direction and place a mark on the damper at the same distance you measured when placing the second damper mark. The damper should now be marked in three equally spaced locations and the damper TDC mark should be in the 12 o'clock position. d. Remove injectors, fuel lines, and high pressure connectors for every cylinder that requires repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 3064 11. Compress the valve springs at cylinders. # 1 and # 6 as follows: a. Install the valve spring compressor mounting base as shown in. b. Install the top plate, washer, and nut. Using a suitable wrench tighten the nut (clockwise) to compress the valve springs and remove the collets. c. Rotate the compressor nut counterclockwise to relieve tension on springs. Remove spring compressor. d. Remove and replace retainers, springs, and seals as necessary. e. Do not rotate the engine until the springs and retainers are reinstalled. f. Install seals, springs and retainers. Install spring compressor, compress valve springs and install the collets. g. Release the spring tension and remove the compressor. Verify that the collets are seated by tapping on the valve stem with a plastic hammer. 12. Using the crankshaft barring tool (2), rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders # 2 and # 5 can be serviced. 13. Repeat the valve spring compressing procedure previously performed and service the retainers, springs, and seals as necessary. 14. Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders # 3 and # 4 can be serviced. 15. Repeat the spring compressing procedure previously performed and service the retainers, springs, and seals as necessary. Installation INSTALLATION 1. Install rocker housing. See: Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Installation 2. Install fuel injectors and high pressure fuel lines. 3. Lubricate the valve tips and install the crossheads in their original locations. 4. Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 Nm (27 ft. lbs.) torque. 5. Verify valve lash adjustment See: Procedures . 6. Install cylinder head cover gasket onto rocker housing. See: Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover Installation 7. Install injector solenoid nuts. 8. Connect injector harness connectors. 9. Install cylinder head cover. See: Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover Installation 10. Connect battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams With A/C 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- A/C Compressor Pulley 7- Accessory Drive Belt Tensioner 8- Generator 9Water Pump Pulley Without A/C Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3069 1- Idler Pulley 2- Accessory Drive Belt 3- Power Steering Pulley 4- Radiator Fan Pulley 5Crankshaft Pulley 6- Accessory Drive Belt Tensioner 7- Generator 8- Water Pump Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3070 Drive Belt: Description and Operation DESCRIPTION The accessory drive belt is a serpentine type belt. Satisfactory performance of these belts depends on belt condition and proper belt tension. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3071 Drive Belt: Testing and Inspection DIAGNOSIS AND TESTING VISUAL DIAGNOSIS NOTE: Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor ( located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib , are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3072 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 3073 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 3076 Drive Belt: Removal and Replacement Accessory Drive Belt - Removal 6.7L DIESEL Belt Routing-Diesel Engine Without A/C 1. A 1/2 inch square hole is provided in the automatic belt tensioner. Attach a suitable tool into this hole. BELT ROUTING-DIESEL WITH A/C 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from water pump pulley first. 4. Remove belt from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 3077 Accessory Drive Belt - Installation 6.7L DIESEL Belt Routing - DIESEL WITH A/C CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. 1. Position drive belt over all pulleys except water pump pulley. 2. Attach a suitable tool to the accessory drive belt tensioner. Belt Routing - DIESEL WITHOUT A/C 3. Rotate accessory drive belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove tool. Be sure belt Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 3078 is properly seated on all pulleys. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Description Drive Belt Tensioner: Description and Operation Description DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Description > Page 3083 Drive Belt Tensioner: Description and Operation Operation OPERATION The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - Removal 6.7L DIESEL WARNING: Because of high spring pressure, do not attempt to disassemble automatic tensioner. Unit is serviced as an assembly. 1. Remove accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Removal . 2. Remove tensioner mounting bolt and remove tensioner (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal > Page 3086 Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - Installation 6.7L DIESEL 1. Install tensioner assembly (7) to water inlet bracket. A dowel is located on back of tensioner. Align this dowel to hole in tensioner mounting bracket. Tighten bolt to 43 Nm (32 ft. lbs.) torque. 2. Install drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount - Removal Engine Mount: Service and Repair Engine Mount - Removal Front Engine Mount REMOVAL CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. Disconnect the battery negative cables. 2. Remove the viscous fan/drive assembly See: Cooling System/Radiator Cooling Fan/Service and Repair/Removal and Replacement/Radiator Fan Removal . 3. Raise vehicle on hoist. 4. Install engine support fixture tool# 8534 and steel bracket tool # 8534A 5. Loosen the thru-bolt and nut. 6. Lift the engine SLIGHTLY and remove the insulator to block bolts. 7. Remove the RH mount (2) from the engine. 8. Remove the LH insulator (2) from the vehicle. Rear Engine Mount REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount - Removal > Page 3091 CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. Raise the vehicle on a hoist. 2. Position a transmission jack in place. 3. Remove support cushion stud nuts (6). 4. Raise rear of transmission until cushion studs (6) clear frame. 5. Remove the nuts holding the support cushion (5) to the transmission support bracket (8). 6. Remove support cushion (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount - Removal > Page 3092 7. Remove the bolts (3) holding the transmission support to the bracket (4). 8. Remove the bolts (7) holding the transmission support to the transmission. 9. Remove the transmission support (8). 10. Remove the nuts (1) from the transmission bracket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount - Removal > Page 3093 11. Remove the bracket (3) from the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount - Removal > Page 3094 Engine Mount: Service and Repair Engine Mount - Installation Front Engine Mount INSTALLATION CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this caution may result in damage to the vehicle. 1. With engine raised SLIGHTLY, position the LH insulator (2) to the mount. Install the bolts and torque to specification. 2. With engine raised SLIGHTLY, position the RH insulator (2) to the mount. Install the bolts and torque to specification. 3. Lower the engine using tool # 8534, while guiding the mount and thru-bolt into the frame mounted support cushion brackets. 4. Install the thru bolt nut and tighten the nut to 95 Nm (70 ft. lbs.) torque. 5. Remove the engine support fixture tool # 8534. 6. Lower the vehicle. 7. Install the viscous fan/drive assembly. 8. Connect the battery negative cables. Rear Engine Mount INSTALLATION CAUTION: If replacing a engine mount / bracket, be certain to inspect all other engine mounts / brackets in the system. Failure to follow this Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount - Removal > Page 3095 caution may result in damage to the vehicle. 1. If removed, position the brackets to the transmission. Install attaching fasteners (1,2), Do not tighten at this time.. 2. Position support cushion (5) to transmission support bracket (3). Install stud nuts (4) and tighten to 61 Nm (45 ft. lbs.) torque. 3. Position assembled support cushion (5) and bracket (3) to transmission. 4. Install the support bracket bolt (7) and tighten to 54 Nm (40 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount - Removal > Page 3096 5. Install the support bracket bolts (3) and tighten to 50 Nm (37 ft. lbs.) torque. 6. Torque the bracket to transmission nuts (11) to 30 Nm (22 ft. lbs.) torque. 7. Using the transmission jack, lower the transmission and support cushion (5) onto the crossmember. 8. Install the support cushion nuts (6) and tighten to 61 Nm (45 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount - Removal > Page 3097 9. Remove the transmission jack. 10. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection Engine Oil Pressure: Testing and Inspection ENGINE OIL PRESSURE 1. Remove the 1/8 NPT plug from the top of the oil filter housing. 2. Install Oil Pressure Line and Gauge Tool C-3292 with a suitable adapter. 3. Start engine and warm to operating temperature. 4. Record engine oil pressure and compare with engine oil pressure chart. CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE. If minimum engine oil pressure is below these ranges, Refer to appropriate testing. 5. Remove oil pressure gauge and install the 1/8 NPT plug. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3106 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Oil Capacity ......................................................................................................................................... ......................................................... 11.4L (12.0 Qt) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3109 Engine Oil: Fluid Type Specifications Engine Oil ............................................................................................................................................ ............................................................. SAE 15W-40 API CJ-4 Certified, that meets CES 20081 Standards Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 3110 Engine Oil: Description and Operation ENGINE OIL - DIESEL ENGINES Use only Low Ash Diesel Engine Oil meeting standard MIL-2104C or API Classification CJ-4/SM (5.9L), or CJ-4 (6.7L), or higher that meets Cummins CES 20081 Standards. Low ash diesel engine oil is REQUIRED for the 6.7L engine, use MOPAR (R) MaxPro15W40 6700 Diesel DPF diesel engine oil, or equivalent. SAE VISCOSITY GRADE CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation. To assure of properly formulated engine oils, it is recommended that SAE Grade 15W-40 engine oils that meet Chrysler material standard MS-10902, be used in accordance to ACEA B3, B4 specification. European Grade 15W-40 oils that meet Association des Constructeurs EuropA■©ens d' Automobiles (European Automobile Manufacturers Association) (ACEA) specifications, are also acceptable. Oils of the SAE 5W-40 grade number are preferred when minimum temperatures consistently fall below -15° C (5° F). ACEA Categories For countries that use the ACEA European Oil Categories for Service Fill Oils, use engine oils that meet the requirements of ACEA A1/B1, A2/B2, or A3/B3. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Service Engine Oil: Service and Repair Engine Oil Service ENGINE OIL SERVICE WARNING: Hot oil can cause personal injury. 1. Operate the engine until the water temperature reaches 60°C (140°F). Shut the engine off. 2. Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and drain the used engine oil into the container. 3. Always check the condition of the used oil. This can give you an indication of engine problems that might exist. - Thin, black oil indicates fuel dilution. - Milky discoloration indicates coolant dilution. 4. Clean the area around the oil filter head. Remove the filter See: Oil Filter/Service and Repair/Removal . 5. Install new oil filter See: Oil Filter/Service and Repair/Installation . 6. Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and sealing surface on the oil pan and drain plug. 7. Install the drain plug. Tighten the plug to 50 Nm (37 ft. lbs.) torque. 8. Use only High-Quality Low Ash Multi-Viscosity lubricating oil in the Cummins Turbo Diesel engine. Choose the correct oil for the operating conditions. 9. Fill the engine with the correct grade of new oil See: Maintenance . 10. Start the engine and operate it at idle for several minutes. Check for leaks at the filter and drain plug. 11. Stop engine. Wait 30 minutes to allow the oil to drain back to the pan and check the level again. USED ENGINE OIL DISPOSAL Care should be exercised when disposing of used engine oil after it has been drained from a vehicle's engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Service > Page 3113 Engine Oil: Service and Repair Engine Oil Level ENGINE OIL LEVEL CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE (3) on the engine oil dipstick. NOTE: Note: The best time to check the engine oil level is after the engine is at operating temperature and has been turned off (not running) for 30 minutes. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately 30 minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Replace dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the SAFE RANGE area on the dipstick. 7. Replace dipstick. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Procedures Oil Cooler: Procedures CLEANING AND INSPECTION Clean the sealing surfaces. Apply 483 kPa (70 psi) air pressure to the element to check for leaks. If the element leaks, replace the element. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Procedures > Page 3118 Oil Cooler: Removal and Replacement Engine Oil Cooler - Removal REMOVAL - OIL COOLER 1. Disconnect Negative battery cables See: Starting and Charging/Battery/Battery Cable/Service and Repair/Battery Cables - Removal 2. Drain Coolant. See: Cooling System/Service and Repair 3. Disconnect Ambient Air and MAF Sensors on Air Filter housing. 4. Loosen hose clamp at Turbocharger Inlet. 5. Move clamp on Engine Breather hose at Inlet elbow at turbocharger and remove hose. 6. Remove Air Filter housing cover and inlet hose and set aside. See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Removal 7. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head. See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator - Removal 8. Loosen the three clamps and hoses from the Coolant outlet tube. 9. Loosen and remove the bracket attachment nut from Coolant tube (10 mm). 10. Remove Coolant outlet tube. 11. Loosen turbocharger oil supply hose from oil cooler housing. 12. Remove oil filter. See: Oil Filter/Service and Repair/Removal 13. Loosen and remove the 14 oil cooler attachment capscrews (10 mm). 14. Remove oil cooler housing and oil cooler from engine block. Engine Oil Cooler - Installation INSTALLATION 1. Clean block surface, oil cooler, and oil cooler housing of debris, dirt and remaining gasket material 2. Using new gaskets install oil cooler, oil cooler housing to cylinder block. NOTE: Depending on the revision of oil cooler, mounting gaskets will differ. Make sure the gaskets line up with the oil cooler element and housing correctly. Failure to use correct gaskets will result in severe engine damage. 3. Tighten mounting capscrews in a criss-cross pattern. Torque to 24 N.m (18 ft-lb) 4. Install Coolant outlet tube into place and secure tube bracket to cooler mounting stud. Tighten nut to 24 Nm (18 ft-lb 5. Connect tube to hoses and secure with hose clamps 6. Swing generator into place and torque through bolts to spec. 7. Install Air Inlet hose to turbocharger and place Air Filter housing lid into place 8. Tighten hose clamp at Turbocharger to spec.. 9. Install Crank Case Breather hose to Inlet elbow and place hose clamp in place 10. Connect Ambient Air and MAP sensors 11. Fill Engine with coolant See: Cooling System/Service and Repair 12. Connect battery cables 13. Start engine and check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Page 3119 Oil Cooler: Tools and Equipment 1/2" Oil Cooler Line Rem. AST tool# 8016 Used for removing both of the oil cooler lines from the fittings on automatic transmission and oil coolers. - Used for R and R of Oil and Transmission Cooler Lines - Green-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Page 3120 8107 - 7-Piece Line Disconnect Set 8110 - 10-Pc. Line Disconnect Set Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Removal Oil Filter: Service and Repair Removal REMOVAL 1. Clean the area around the oil filter head. Remove the filter from below using a cap-style filter wrench. 2. Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure it is removed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Removal > Page 3125 Oil Filter: Service and Repair Installation INSTALLATION 1. Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine. 2. Apply a light film of lubricating oil to the sealing surface before installing the filter. CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal. 3. Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional 1/2 turn. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Starting in the center and working outward, tighten the oil pan bolts to 28 Nm (21 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Procedures Oil Pan: Procedures Cleaning CLEANING Remove all gasket material from the oil pan and cylinder block sealing surfaces. Extra effort may be required around T-joint areas. Clean oil pan and flush suction tube with a suitable solvent. Inspection INSPECTION Inspect the oil pan, suction tube, and tube braces for cracks and damage. Replace any defective component. Inspect the oil drain plug and drain hole threads. Inspect the oil pan sealing surface for straightness. Repair any minor imperfections with a ball-peen hammer. Do not attempt to repair an oil pan by welding. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Procedures > Page 3131 Oil Pan: Removal and Replacement Engine Oil Pan - Removal REMOVAL 4x4 1. Open the hood. 2. Disconnect the battery negative cables. 3. Remove the intake air assembly. 4. Remove the radiator shroud retaining bolts. 5. Install engine support fixture # 8534B. 6. Raise and support the vehicle. WARNING: HOT OIL CAN CAUSE PERSONAL INJURY. 7. Drain the engine oil See: Engine Oil/Service and Repair . 8. Loosen the front engine mount bolts. 9. Lower the vehicle. 10. Use the engine support fixture #8534B to raise engine out of the front mounts. 11. Remove the engine oil dipstick. 12. Raise and support the vehicle. 13. Remove oil pan bolts, break the pan to block seal, and lower pan slightly and remove oil suction tube fasteners. 14. Remove oil pan and suction tube. 15. Remove the 2 bolts from the front of the engine block stiffener. 16. Remove the oil pan. 4x2 1. Open the hood. 2. Remove the negative battery cables. 3. Raise and support the vehicle. 4. Remove the transmission oil cooler lines. 5. Remove the propeller shaft. 6. Remove the starter bolts. 7. Support the starter. 8. Remove the torque converter bolts. 9. Remove the exhaust hanger bolts. 10. Remove the gear shift cable. 11. Remove the wiring harness. 12. Remove the transmission mount. 13. Remove the crossover bolts. 14. Position the transmission jack. 15. Remove the bell housing bolts. 16. Remove the transmission. 17. Remove the flywheel housing bolts (8). 18. Remove the flex plate bolts (8). 19. Remove the engine oil dip stick. 20. Drain the oil. 21. Remove the steering rack bolts. 22. Remove the oil pan bolts. 23. Remove the oil pickup bolts. 24. Remove the oil pan. Engine Oil Pan - Installation INSTALLATION 4x4 1. Clean the sealing surfaces of the cylinder block and oil pan with a suitable cleaner. 2. Clean the oil pan. 3. Clean the oil pan T-joints. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Procedures > Page 3132 4. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar(R) Silicone Rubber Adhesive Sealant or equivalent. 5. Position the new oil pan gasket. 6. Place suction tube in oil pan and guide them into place. Using a new tube-to-block gasket, install and tighten the suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24 Nm (18 ft. lbs.) torque. Tighten the remaining tube brace bolts to 43 Nm (32 ft. lbs.) torque. 7. Starting in the center and working outward, tighten the oil pan bolts to 28 Nm (21 ft. lbs.) torque. 8. Install the engine oil dipstick. 9. Install the engine block stiffener. 10. Install the flywheel to crankshaft adapter. Torque to 137 Nm (101 ft. lbs.). 11. Lower vehicle. 12. Lower the engine into the motor mounts and tighten the through bolts to 88 Nm (64 ft. lbs.). 13. Remove the engine support fixture #8534. 14. Install battery negative cables. 15. Fill the crankcase with new engine oil. 16. Start engine and check for leaks. Stop engine, check oil level, and adjust, if necessary. 17. Remove the engine support fixture #8534B. 18. Install the fan and fan shroud. NOTE: Make sure that the fan shroud seal is properly seated in the radiator fan shroud and that it is not out of position causing excessive contact with the radiator coolant tubes. 19. Fill the engine oil. 20. Connect the battery negative cables. 21. Close the hood. 4x2 1. Clean the sealing surfaces of the cylinder block and oil pan with a suitable cleaner. 2. Clean the oil pan. 3. Clean the oil pan T-joints. 4. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar(R) Silicone Rubber Adhesive Sealant or equivalent. 5. Position the new oil pan gasket. 6. Place suction tube in oil pan and guide them into place. Using a new tube-to-block gasket, install and tighten the suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24 Nm (18 ft. lbs.) torque. Tighten the remaining tube brace bolts to 43 Nm (32 ft. lbs.) torque. 7. Starting in the center and working outward, tighten the oil pan bolts to 28 Nm (21 ft. lbs.) torque. 8. Install the steering rack bolts. 9. Install the flex plate. 10. Install the flywheel to crankshaft adapter. Torque to 137 Nm (101 ft. lbs.). 11. Install transmission and transfer case (if equipped). 12. Install the flywheel housing assembly with the starter motor attached and tighten bolts to 77 Nm (57 ft. lbs.) torque. NOTE: A new clamping ring must be used on early or late builds, automatic or manual. Do not reuse clamping ring. 13. Install the EGR cooler. See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Removal and Replacement/EGR Cooler - Installation 14. Install the fan and fan shroud. NOTE: Make sure that the fan shroud seal is properly seated in the radiator fan shroud and that it is not out of position causing excessive contact with the radiator coolant tubes. 15. Remove the transmission jack. 16. Install the crossmember bolts. 17. Install the transmission mount. 18. Install the wiring harness. 19. Install the gear shift cable. 20. Install the exhaust hanger bolts. 21. Install the torque converter bolts. 22. Install the starter. 23. Install the starter bolts. 24. Install the transmission oil cooler lines. 25. Connect the negative battery cables. 26. Close the hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Description Oil Pressure Gauge: Description and Operation Description DESCRIPTION An oil pressure gauge is standard equipment on all instrument clusters except for ST vehicles with a gasoline engine. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from L (or Low) to H (or High) for gasoline engines. On vehicles with a diesel engine the scale reads from 0 kPa to 760 kPa in markets where a metric instrument cluster is specified, or from 0 psi to 110 psi in all other markets. An International Control and Display Symbol icon for Engine Oil is located on the cluster overlay, directly below the left end of the gauge scale. The oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Description > Page 3137 Oil Pressure Gauge: Description and Operation Operation OPERATION The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives an electronic engine oil pressure message from the PCM or ECM indicating the pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. Engine Oil Pressure Low Message - Each time the cluster receives three consecutive electronic engine oil pressure messages from the PCM or ECM indicating the pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn ON the check gauges indicator in response to a low pressure message if the engine speed is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engines) or ECM (diesel engines) continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to oil pressure gauge operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 496 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G6 18VT/GY OIL PRESSURE SIGNAL Pin Circuit Description 1 G6 16VT/GY OIL PRESSURE SIGNAL 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3141 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3142 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3143 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3144 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3145 Oil Pressure Sender: Diagrams Component ID: 496 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G6 18VT/GY OIL PRESSURE SIGNAL Pin Circuit Description 1 G6 16VT/GY OIL PRESSURE SIGNAL 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3146 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3147 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3148 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 3149 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure Sensor/Switch - Installation Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor/Switch - Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure Sensor/Switch - Installation > Page 3152 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor/Switch - Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Description Oil Pressure Warning Lamp/Indicator: Description and Operation Description DESCRIPTION A low oil pressure indicator is standard equipment only in the four-gauge instrument clusters of all ST vehicles with a gasoline engine. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The low oil pressure indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine Oil in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low oil pressure indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Description > Page 3157 Oil Pressure Warning Lamp/Indicator: Description and Operation Operation OPERATION The low oil pressure indicator gives an indication to the vehicle operator when the engine oil pressure reading reflects a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The low oil pressure indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the low oil pressure indicator for the following reasons: - Engine Oil Pressure Low Message - Each time the cluster receives an electronic engine oil pressure message from the PCM indicating the pressure is about 6.9 kPa (1 psi) or lower, the low oil pressure indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the pressure is above about 6.9 kPa (1 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the indicator ON in response to low engine oil pressure if the engine speed is greater than zero. Actuator Test - Each time the cluster is put through the actuator test, the low oil pressure indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the low oil pressure indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the engine oil pressure sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to low oil pressure indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection Engine Oil Pressure: Testing and Inspection ENGINE OIL PRESSURE 1. Remove the 1/8 NPT plug from the top of the oil filter housing. 2. Install Oil Pressure Line and Gauge Tool C-3292 with a suitable adapter. 3. Start engine and warm to operating temperature. 4. Record engine oil pressure and compare with engine oil pressure chart. CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE. If minimum engine oil pressure is below these ranges, Refer to appropriate testing. 5. Remove oil pressure gauge and install the 1/8 NPT plug. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Procedures Oil Pressure Regulator Valve: Procedures Cleaning CLEANING 1. Clean the regulator spring and plunger with a suitable solvent and blow dry with compressed air. If the plunger bore requires cleaning, it is necessary to remove the oil filter head to avoid getting debris into the engine. Inspection INSPECTION Inspect the plunger and plunger bore for cracks and excessive wear. Polished surfaces are acceptable. Verify that the plunger moves freely in the bore. Check the spring for height and load limitations. Replace the spring if out of limits shown in the figure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Procedures > Page 3166 Oil Pressure Regulator Valve: Removal and Replacement Engine Oil Pressure Relief Valve - Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove the threaded plug (2), spring (4) and valve (5). Insert a finger or a seal pick to lift the plunger from the bore. NOTE: If the plunger is stuck in the bore, it will be necessary to remove the filter head. Engine Oil Pressure Relief Valve - Installation INSTALLATION 1. Install the plunger, spring, and plug as shown in. Tighten the plug to 80 Nm (59 ft. lbs.) torque. 2. Connect the battery negative cables. 3. Start the engine and verify that it has oil pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake Manifold Torque the intake manifold capscrews to 24 N.m (18 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures Intake Manifold: Procedures Intake Manifold - Cleaning CLEANING Clean manifold in solvent and blow dry with compressed air. Clean cylinder block gasket surfaces using a suitable solvent. The plenum pan rail must be clean and dry (free of all foreign material). Intake Manifold - Inspection INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straightedge. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 3172 Intake Manifold: Removal and Replacement Intake Manifold - Removal REMOVAL 1. Disconnect the batteries. See: Starting and Charging/Battery/Battery Cable/Service and Repair/Battery Cables - Removal 2. Disconnect the EGR air Transfer tube temperature sensor. 3. Disconnect the EGR Valve Actuator Connector 4. Disconnect the Engine Oil level tube at the Air Inlet bracket 5. Loosen the CAC Outlet tube clamps at the CAC Outlet and Air Inlet and remove the tube. See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Removal 6. Loosen and remove both v-band clamps at each end of the Air Transfer tube 7. Remove the P-clip mounting capscrew 8. Remove the Air Transfer tube 9. Loosen and remove six (6) Air Inlet mounting capscrews. 10. Remove the air inlet. 11. Remove the injector fuel lines. 12. Disconnect the Fuel Rail Pressure sensor at the rear of the fuel rail manifold. 13. Remove the High Pressure fuel line from the dump/overflow valve. 14. Remove the fuel rail. 15. Remove the grid heater wiring connector. 16. Disconnect the MAP sensor. 17. Remove the intake manifold capscrews. 18. Remove the intake manifold. Intake Manifold - Installation INSTALLATION 1. Clean the Intake Manifold and Cylinder Head Gasket area. 2. Install a new intake manifold gasket. 3. Position the intake manifold and Install the intake manifold capscrews finger tight. 4. Position the fuel rail and install the fuel rail manifold capscrews finger tight. 5. Torque the intake manifold capscrews to 24 N.m (18 ft. lbs.). 6. Connect the fuel rail pressure sensor. 7. Connect the intake manifold grid heater. Torque the capscrew to 10 N.m (89 in. lbs.). 8. Install the fuel lines. See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair/Installation 9. Torque the fuel rail mounting capscrews to 24 N.m (18 ft. lbs.). 10. Clean the Air Inlet gasket area. 11. Clean the Intake Manifold to air inlet area. 12. Install the new Air Intake connection gasket. 13. Install the air intake connection to the intake manifold 14. torque the intake manifold to 24 N.m (18 lbs. ft.). 15. Install the Oil Level Gauge tube and torque to 24 N.m (18 lbs. ft.). 16. Clean the gasket area of the Air Transfer Tube (both ends). 17. Clean the EGR cooler and EGR control valve gasket area. 18. Using new gaskets, install the Air Transfer Tube. 19. Install the V-band clamps. 20. Install the P-clip to the bracket. Torque the mounting capscrew to 24 N.m (18 lbs. ft.). 21. Torque the V-band clamps to 10 N.m (89 lbs. in.). 22. Connect the EGR Valve Actuator connector. 23. Connect the EGR Gas Temperature connector. 24. Connect the batteries. 25. Start the engine and check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Description Oil Pressure Gauge: Description and Operation Description DESCRIPTION An oil pressure gauge is standard equipment on all instrument clusters except for ST vehicles with a gasoline engine. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from L (or Low) to H (or High) for gasoline engines. On vehicles with a diesel engine the scale reads from 0 kPa to 760 kPa in markets where a metric instrument cluster is specified, or from 0 psi to 110 psi in all other markets. An International Control and Display Symbol icon for Engine Oil is located on the cluster overlay, directly below the left end of the gauge scale. The oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Description > Page 3178 Oil Pressure Gauge: Description and Operation Operation OPERATION The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. Each time the cluster receives an electronic engine oil pressure message from the PCM or ECM indicating the pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. Engine Oil Pressure Low Message - Each time the cluster receives three consecutive electronic engine oil pressure messages from the PCM or ECM indicating the pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn ON the check gauges indicator in response to a low pressure message if the engine speed is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engines) or ECM (diesel engines) continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster turns ON the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to oil pressure gauge operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Description Oil Pressure Warning Lamp/Indicator: Description and Operation Description DESCRIPTION A low oil pressure indicator is standard equipment only in the four-gauge instrument clusters of all ST vehicles with a gasoline engine. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The low oil pressure indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine Oil in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low oil pressure indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Description > Page 3183 Oil Pressure Warning Lamp/Indicator: Description and Operation Operation OPERATION The low oil pressure indicator gives an indication to the vehicle operator when the engine oil pressure reading reflects a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The low oil pressure indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the low oil pressure indicator for the following reasons: - Engine Oil Pressure Low Message - Each time the cluster receives an electronic engine oil pressure message from the PCM indicating the pressure is about 6.9 kPa (1 psi) or lower, the low oil pressure indicator will be illuminated. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the pressure is above about 6.9 kPa (1 psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the indicator ON in response to low engine oil pressure if the engine speed is greater than zero. Actuator Test - Each time the cluster is put through the actuator test, the low oil pressure indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the low oil pressure indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the engine oil pressure sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to low oil pressure indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal Crankshaft Main Bearing Seal: Service and Repair Removal REMOVAL 1. Disconnect the battery negative cables. 2. Remove the transmission and transfer case (if equipped). 3. Remove the clutch cover and disc (if manual transmission equipped) See: Transmission and Drivetrain/Clutch/Clutch Disc/Service and Repair/Clutch Disc - Removal . 4. Remove the flywheel or converter drive plate. 5. Remove the flywheel adapter plate. 6. Drill holes 180° apart into the seal. Be careful not to contact the drill against the crankshaft. 7. Install # 10 sheet metal screws (1) in the drilled holes and remove the rear seal with a slide hammer (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal > Page 3189 Crankshaft Main Bearing Seal: Service and Repair Installation INSTALLATION CAUTION: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. The crankshaft and seal surfaces must be completely dry when the seal is installed. Use a soap and water solution on outside diameter of seal to ease assembly. 1. Clean the crankshaft journal with a suitable solvent and dry with a clean shop towel or compressed air. Wipe the inside bore of the crankshaft seal retainer with a clean shop towel. 2. Inspect the crankshaft journal for gouges, nicks, or other imperfections. If the seal groove in the crankshaft is excessively deep, install the new seal 1/8" deeper into the retainer bore, or obtain a crankshaft wear sleeve that is available in the aftermarket. 3. Install the seal pilot and new seal, provided in the replacement kit, onto the crankshaft. 4. Remove the seal pilot. 5. Install the installation tool over crankshaft. 6. Using a ball peen hammer, strike the tool (2) at the 12, 3, 6, and 9 o'clock positions until the alignment tool bottoms out on the retainer. NOTE: Always install a new clamping ring, never reuse the old clamping ring. 7. Install the flywheel or converter drive plate, and clamping ring. Tighten the bolts to 137 Nm (101 ft. lbs.) torque. 8. Install the clutch cover and disc (if equipped) See: Transmission and Drivetrain/Clutch/Clutch Disc/Service and Repair/Clutch Disc - Installation . 9. Install the transmission and transfer case (if equipped). 10. Lower vehicle. 11. Connect battery negative cables. 12. Check engine oil level and adjust, if necessary. 13. Start engine and check for oil leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal Front Crankshaft Seal: Service and Repair Removal REMOVAL 1. Disconnect both battery negative cables. 2. Raise vehicle on hoist. 3. Partially drain engine coolant into container suitable for re-use See: Cooling System/Service and Repair . 4. Lower vehicle. 5. Remove radiator upper hose. 6. Disconnect coolant recovery bottle hose from radiator filler neck. 7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan shroud. 8. Remove viscous fan/drive assembly. See: Cooling System/Radiator Cooling Fan/Service and Repair/Removal and Replacement/Radiator Fan Removal . 9. Remove cooling fan shroud and fan assembly from the vehicle. 10. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Removal . 11. Remove the cooling fan support/hub from the front of the engine. 12. Raise the vehicle on hoist. 13. Remove the crankshaft damper. 14. Remove power steering pump. 15. Remove accessory drive belt tensioner. 16. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. Remove crank seal dust shield with cover. 17. Support the cover on a flat work surface with wooden blocks, and using a suitable punch (1) and hammer, drive the old seal out of the cover from the back side of the cover to the front side. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal > Page 3194 Front Crankshaft Seal: Service and Repair Installation INSTALLATION CAUTION: The seal lip and the sealing surface on the crankshaft must be free of all oil residue, to prevent leaks. The crankshaft and seal surface must be completely dry when the seal is installed. 1. Clean cover and housing gasket mating surfaces. Use a suitable scraper and be careful not to damage the gear housing surface. Remove any old sealer from the oil seal bore. Thoroughly clean the front seal area of the crankshaft. Do not sand this surface. The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. 2. Inspect the gear housing and cover for cracks and replace if necessary. Carefully straighten any bends or imperfections in the gear cover with a ball-peen hammer on a flat surface. Inspect the crankshaft front journal for any grooves or nicks that would affect the integrity of the new seal. 3. Apply a bead of Mopar(R) Stud & Bearing Mount to the outside diameter of the seal. Do not lubricate the inside diameter of the new seal. 4. With the cover supported by wood blocks, install the seal into the rear of the cover using crankshaft seal installer Special Tool 8281 and driver handle C-4171. Strike the driver handle until the installation tool bottoms out on the inside of the cover. CAUTION: Do not distort or damage seal. 5. Install the plastic seal pilot (provided with seal kit) into the crankshaft seal. 6. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover sealing surface. 7. Install the cover to the gear housing, aligning the seal pilot with the nose of the crankshaft. NOTE: Failure to follow the cover installation procedure can result in misalignment of the crankshaft seal to the crankshaft, causing an oil leak. 8. Install the cover bolts and hand snug 2 capscrews at the 3 o'clock and 9 o'clock position, to keep the cover from moving when the first capscrew is torqued. Torque to 24 Nm (18 ft. lbs.) torque. Remove pilot tool. 9. Install dust shield over nose of crankshaft. 10. Install the crankshaft damper. Torque the bolts to 40 Nm (30 ft. lbs.). Then rotate an additional 60°. Use the engine barring tool to keep the engine from rotating during tightening operation. 11. Install the fan support/hub assembly and torque bolts to 32 Nm (24 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Removal > Page 3195 12. Install power steering pump. 13. Install accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft.lbs.). 14. Install cooling fan. 15. Install the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Installation . 16. Refill cooling system See: Cooling System/Service and Repair . 17. Connect battery negative cables. 18. Start engine and check for oil leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Oil Pan Gasket, Engine > Component Information > Service and Repair > Removal Oil Pan Gasket: Service and Repair Removal REMOVAL 1. Disconnect the battery. 2. Remove the intake air assembly. 3. Remove the inner radiator shroud retaining bolts. 4. Remove the inner radiator shroud. 5. Raise and support the vehicle. 6. Remove the front suspension rear tie bar. 7. Remove the left engine mount through bolt. 8. Remove the right engine mount through bolt. 9. Remove the rack and pinion retaining bolts. 10. Drain the engine oil. 11. Lower the vehicle. 12. Install the engine lift fixture. 13. Use the engine lift fixture to raise the engine. 14. Raise the vehicle on the hoist. 15. Remove the oil pan retaining bolts. 16. Lower the oil pan enough to allow the removal of the oil pan gasket. 17. Remove the oil pan gasket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Oil Pan Gasket, Engine > Component Information > Service and Repair > Removal > Page 3200 Oil Pan Gasket: Service and Repair Installation INSTALLATION 1. Clean the oil pan gasket surfaces to be sure the surfaces are free of debris and oil. 2. Install a new oil pan gasket. 3. Install the oil pan bolts in a cross pattern. 4. Install the rack and pinion bolts. 5. Lower the vehicle. 6. Lower the engine into the mounts. 7. Remove the engine lift fixture. 8. Fill the engine with oil. 9. Raise and support the vehicle. 10. Install the left engine mount through bolt. 11. Install the right engine mount through bolt. 12. Install the front suspension rear tie bolts. 13. Lower the vehicle. 14. Install the radiator shroud. 15. Install the radiator shroud bolts. 16. Install the intake air assembly. 17. Connect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair For information regarding Valve Guide Seal service, please refer to Valve Spring service procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Component ID: 496 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G6 18VT/GY OIL PRESSURE SIGNAL Pin Circuit Description 1 G6 16VT/GY OIL PRESSURE SIGNAL 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3208 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3209 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3210 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3211 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3212 Oil Pressure Sender: Diagrams Component ID: 496 Component : SWITCH-OIL PRESSURE Connector: Name : SWITCH-OIL PRESSURE Color : BLACK # of pins : 2 Pin Circuit Description 1 G6 18VT/GY OIL PRESSURE SIGNAL Pin Circuit Description 1 G6 16VT/GY OIL PRESSURE SIGNAL 2-Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3213 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3214 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3215 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 3216 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure Sensor/Switch - Installation Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor/Switch - Installation INSTALLATION 1. Install banjo screw through the oil pressure switch mounting block. The switch mounting block port (oil switch port) should point to the 2 o'clock position. Torque the banjo screw to 24 Nm or 18 ft lbs. 2. If the switch is not being replaced, replace and lubricate the o-ring. 3. Install the oil pressure switch and tighten to 18 Nm (159 in. lbs.) torque. 4. Connect oil pressure switch connector. 5. Connect the battery negative cables. 6. Start engine and check for oil leaks at the switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Service and Repair > Engine Oil Pressure Sensor/Switch - Installation > Page 3219 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor/Switch - Removal REMOVAL NOTE: When installing a new oil pressure switch, the kit will include a special 90° fitting that must be installed. Clock the fitting and switch assembly between the 1:00 o'clock and 2:00 o'clock position. Torque the fitting bolt to 18 Nm (13 ft. lbs) 1. Disconnect the battery negative cables. 2. Disconnect the oil pressure switch connector. 3. Using a suitable socket, remove the oil pressure switch from the block (counter-clockwise). 4. Remove the banjo screw from the oil pressure switch mounting block. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Damper Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal Timing Chain: Service and Repair Removal REMOVAL 1. Disconnect the battery negative cables. 2. Raise vehicle on hoist. 3. Partially drain engine coolant into container suitable for re-use See: Cooling System/Service and Repair . 4. Lower vehicle. 5. Remove radiator upper hose. 6. Disconnect coolant recovery bottle hose from radiator filler neck. 7. Remove viscous fan/drive/shroud assembly See: Cooling System/Radiator Cooling Fan/Service and Repair/Removal and Replacement/Radiator Fan - Removal . 8. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Removal . 9. Remove the cooling fan support/hub from the front of the engine. 10. Raise the vehicle on hoist. 11. Remove the crankshaft damper See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Removal and Replacement/Vibration Damper - Removal . 12. Remove the lower fan shroud bracket. 13. Remove the upper fan shroud bracket that is mounted to the gear housing. 14. Lower the vehicle. 15. Remove the power steering pump. 16. Remove the accessory drive belt tensioner. 17. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. 18. Remove the fuel injection pump See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Injection Pump/Removal . 19. Disconnect the camshaft position sensor connector. 20. Disconnect and remove engine speed sensor. 21. Remove the camshaft See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal . 22. Remove the six front oil pan fasteners. 23. Remove the gear housing fasteners. NOTE: Use care when removing the gear housing, to avoid damage to the oil pan gasket, as the gasket will be reused if it is not damaged. 24. Slide a feeler gauge between the gear housing and oil pan gasket, to break the gasket seal. 25. Remove the gear housing and gasket. 26. Clean the gasket material from the cylinder block and gear housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3228 Timing Chain: Service and Repair Installation INSTALLATION 1. Inspect oil pan gasket. If torn, gasket must be replaced. 2. Install a new gear housing gasket onto cylinder block and trim any excess gasket material flush to oil pan rail. 3. Place a small amount of Mopar(R) engine RTV to the corners of the block and pan gasket T-joint to ensure a good seal. 4. Install the gear housing. Torque bolts to 24 Nm (18 ft. lbs.). 5. If a new housing is installed, the camshaft position sensor, and engine speed sensor must be transferred to the new housing. 6. Connect the camshaft position sensor connector. 7. Install and connect engine speed sensor. 8. Install the injection pump See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Injection Pump/Installation . 9. Install the camshaft See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation . Align the crankshaft and camshaft gear marks as shown. 10. Install a new front crankshaft seal into the gear cover. 11. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes. 12. Using the seal pilot to align the cover, install the cover to the housing and install the bolts. Tighten the bolts at the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to 24 Nm (18 Ft lbs). 13. Snug, but do not torque one bolt at the 3 o'clock and 9 o'clock positions. This center's the seal on the crankshaft. 14. Tighten the bolt to 24 Nm (18 ft. lbs.) torque in a circular pattern. 15. Remove the seal pilot. Install front seal dust shield. 16. Raise the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Removal > Page 3229 17. Install the crankshaft damper See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Removal and Replacement/Vibration Damper - Installation . Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°. 18. Install the lower fan shroud bracket. Torque bolts to 24 Nm (18 ft. lbs.) torque. 19. Install the upper fan shroud brackets. Hand tighten only. 20. Lower vehicle. 21. Install the fan support/hub assembly and tighten bolts to 32 Nm (24 ft. lbs.) torque. 22. Install the power steering pump. 23. Install the accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.) torque. 24. Install the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Installation . 25. Install the upper cooling fan/drive/shroud assembly. 26. Torque the upper fan shroud brackets to 24 Nm (18 ft. lbs.) torque. 27. Connect the coolant recovery bottle hose to the radiator filler neck. 28. Install the radiator upper hose and clamps. 29. Add engine oil. 30. Add coolant See: Cooling System/Service and Repair . 31. Connect the battery cables. 32. Start engine and inspect for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Components Crankshaft Damper Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°. Timing Cover Using the seal pilot to align the cover, install the cover to the housing and install the bolts. Tighten the bolts at the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to 24 Nm (18 Ft lbs). Snug, but do not torque one bolt at the 3 o'clock and 9 o'clock positions. This center's the seal on the crankshaft. Tighten the bolts to 24 Nm (18 ft. lbs.) torque in a circular pattern. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Timing Cover - Removal Timing Cover: Service and Repair Timing Cover - Removal REMOVAL 1. Disconnect both battery negative cables. 2. Raise vehicle on hoist. 3. Partially drain engine coolant into container suitable for re-use See: Cooling System/Service and Repair . 4. Lower vehicle. 5. Remove radiator upper hose. 6. Remove viscous fan/drive/shroud assembly See: Cooling System/Radiator Cooling Fan/Service and Repair/Removal and Replacement/Radiator Fan - Removal . 7. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Removal . 8. Remove the cooling fan support/hub from the front of the engine. 9. Raise the vehicle on hoist. 10. Remove power steering pump. 11. Remove accessory drive belt tensioner. 12. Remove the crankshaft damper See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Removal and Replacement/Vibration Damper - Removal . 13. Lower the vehicle. 14. Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Timing Cover - Removal > Page 3235 Timing Cover: Service and Repair Timing Cover - Installation INSTALLATION 1. Install a new front crankshaft oil seal. 2. Obtain a seal pilot (1) installation tool from a crankshaft front seal service kit and install the pilot into the seal. 3. Apply a bead of Mopar(R) Silicone Rubber Adhesive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes. 4. Using the seal pilot to (1) align the cover , install the cover to the housing and install the bolts. Tighten the bolts at the 3 and 9 o'clock position finger tight, then in a clockwise direction starting at the 3 o'clock position, torque to 24 Nm (18 Ft. lbs). 5. Snug, but do not torque one bolt at the 3 o'clock and 9 o'clock positions. This centers the seal on the crankshaft. 6. Tighten the bolts to 24 Nm (18 ft. lbs.) in a circular pattern. 7. Remove the seal pilot. Install front seal dust shield. 8. Raise the vehicle. 9. Install the crankshaft damper See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Removal and Replacement/Vibration Damper - Installation . 10. Lower vehicle. 11. Install the fan support/hub assy, and tighten bolts to 32 Nm (24 ft. lbs.) torque. 12. Install power steering pump. 13. Install accessory drive belt tensioner. Torque bolt to 43 Nm (32 ft. lbs.) torque. 14. Install the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Installation . 15. Install the cooling fan/drive/shroud assembly. 16. Install the radiator upper hose and clamps. 17. Add coolant See: Cooling System/Service and Repair . 18. Connect the battery cables. 19. Start engine and inspect for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder. Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 3242 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than +/- 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 3243 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed Information Not Supplied by the Manufacturer Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL There is no longer a Filter Minder on the MY08 Diesel Engines. There will be an EVIC message which will display when the filter restriction reaches it's maximum. The customer will be required to replace it with-in 250 miles (402 KM) Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 3252 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 3257 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 3258 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description > Page 3261 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel Filter/Water Separator Removal/Installation. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules, for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3264 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3265 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3266 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. Refer to Standard Procedures-Fuel System Priming. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3267 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 3268 a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread O-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. The cylinders are numbered front to rear ; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Specifications Compression Ratio .............................................................................................................................. ....................................................................... 17.2 : 1 Compression Pressure (Minimum) ...................................................................................................... ....................................................................... 350 psi Max Variation Between Cylinders ........................................................................................................ ............................................................ Not available Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60° C (140° F). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover See: Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover Removal . 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjustment/resettingis not necessary. If measurement finds the lash outside of the limits, adjustment/resettingis required. 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > Page 3278 7. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits. 8. Install the cylinder head cover See: Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover Installation . 9. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Tighten mounting bolts to 24 Nm (18 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Description Water Pump: Description and Operation Description Water Pump WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Water Pump Bypass WATER PUMP BYPASS The 3.7L and 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Description > Page 3284 engine warm-up preventing the coolant from flowing through the radiator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Description > Page 3285 Water Pump: Description and Operation Operation Water Pump WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Water Pump Bypass - 3.7L/4.7L WATER PUMP BYPASS - 3.7L/4.7L When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the pill partially covers the bypass hole, reducing the amount of bypass flow. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Page 3286 Water Pump: Testing and Inspection WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Cleaning CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. Inspection INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 3289 Water Pump: Removal and Replacement Water Pump - Removal 6.7L DIESEL 1. Disconnect battery negative cables. 2. Drain cooling system See: Cooling System/Service and Repair . 3. Disconnect ambient air temp sensor electrical connector and mass airflow sensor electrical connector (if equipped). 4. Remove turbocharger inlet tube and air filter housing. For 5.9L Diesel, See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Removal, for 6.7L Diesel, See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing Removal . 5. Remove generator assembly See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator - Removal . 6. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Removal . 7. Remove water pump mounting bolts (3). 8. Remove O-ring from water pump. 9. Clean water pump sealing surface on cylinder block. Water Pump - Installation 6.7L DIESEL 1. Install new O-ring seal in groove on water pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 3290 2. Install water pump with the weep hole facing downward. Tighten mounting bolts to 24 Nm (18 ft. lbs.) torque. 3. Install generator assembly. 4. Install accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Installation . 5. Install air box and tube assembly. For 5.9L Diesel, See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Installation . For 6.7L Diesel, See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Installation . 6. Install air filter housing See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing Installation . 7. Fill cooling system See: Cooling System/Service and Repair . 8. Connect both battery cables. 9. Start and warm the engine. Check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3296 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity ..................................................................................................................... ........................................................ 22.6 qts (21.4L) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3299 Coolant: Fluid Type Specifications ENGINE COOLANT Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Engine Coolant Coolant: Description and Operation Engine Coolant ENGINE COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT) may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic. The increased temperature can result in sever engine damage. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Engine Coolant > Page 3302 Coolant: Description and Operation Coolant Description HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol based coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT) may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic. The increased temperature can result in severe engine damage. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Operation OPERATION Coolant flows through the engine block, cylinder head, absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. On the 6.7L diesel engine, coolant also flows through the EGR cooler and turbocharger actuator. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 3303 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or Tool 8266, refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and are not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description Coolant Reservoir: Description and Operation Description DESCRIPTION The coolant reserve/overflow tank is mounted on top of the fan shroud, and is made of high temperature plastic. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description > Page 3308 Coolant Reservoir: Description and Operation Operation OPERATION The coolant reserve/overflow system works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Container - Removal Coolant Reservoir: Service and Repair Coolant Recovery Container - Removal 6.7L DIESEL 1. Remove overflow hose (5) from radiator (1) 2. Remove mounting bolts (4). 3. Remove coolant recovery bottle (2) from bracket (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Container - Removal > Page 3311 Coolant Reservoir: Service and Repair Coolant Recovery Container - Installation 6.7L DIESEL 1. Position coolant recovery bottle (2) on bracket (3). 2. Install mounting bolts (4). Tighten to 8.5 Nm (75 in. lbs). 3. Install overflow hose (5) onto radiator (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Component ID: 83 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Circuit Description 1 K160 18BR/OR PWM FAN COIL SIGNAL Pin Circuit Description 1 K971 18BR/PK SENSOR GROUND 2 N210 18DB/DG FAN SPEED SENSOR SIGNAL 2 K916 18BR/OR SENSOR GROUND 3 K161 18BR/LB FAN SPEED SENSOR GROUND 3 N27 18DB/GY FAN SPEED SENSOR SIGNAL 4-5 K668 18BR 5 VOLT SUPPLY 5 F855 18PK/YL 5 VOLT SUPPLY 6 A212 18PK/YL FUSED B(+) 6 K161 18BR/LB FAN SPEED SENSOR GROUND Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3316 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3317 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3318 Radiator Cooling Fan Control Module: Diagrams Component ID: 83 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Circuit Description 1 K160 18BR/OR PWM FAN COIL SIGNAL Pin Circuit Description 1 K971 18BR/PK SENSOR GROUND 2 N210 18DB/DG FAN SPEED SENSOR SIGNAL 2 K916 18BR/OR SENSOR GROUND 3 K161 18BR/LB FAN SPEED SENSOR GROUND 3 N27 18DB/GY FAN SPEED SENSOR SIGNAL 4-5 K668 18BR 5 VOLT SUPPLY 5 F855 18PK/YL 5 VOLT SUPPLY 6 A212 18PK/YL FUSED B(+) 6 K161 18BR/LB FAN SPEED SENSOR GROUND Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3319 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3320 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3332 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3336 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3337 Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3345 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3346 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3347 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3348 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3349 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3350 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3351 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3352 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3353 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3354 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3355 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3356 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3357 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description Heater Core: Description and Operation Description DESCRIPTION The heater core (1) is a heat exchanger made of rows of tubes and fins. The heater core is positioned within the HVAC housing through the panel (2) located at the front of the HVAC housing. The heater core tubes (3) are attached to the front of the heater core and are secured to the HVAC housing by a bracket. The heater core can be serviced by removing the HVAC housing assembly from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description > Page 3362 Heater Core: Description and Operation Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and must be replaced if restricted, leaking or damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation Heater Core: Service and Repair Installation INSTALLATION 1. Carefully install the heater core (3) into the front of the HVAC housing. 2. Position the heater core tube bracket (2) onto the HVAC housing. 3. Install the two screws (1) that secure the heater core bracket to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.). 4. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 5. Install the foam seal onto the heater core tubes. NOTE: If the heater core is being replaced, flush the cooling system See: Service and Repair. 6. Install the HVAC housing See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation > Page 3365 Heater Core: Service and Repair Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Removal and Installation . 2. Remove the foam seal from the heater core tubes. 3. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 4. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 5. Carefully pull the heater core out of the front of the HVAC housing. 6. Inspect all foam seals and replace as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Description Temperature Gauge: Description and Operation Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines. On vehicles with a diesel engine, the scale reads from 60 °C to 120 °C in markets where a metric instrument cluster is specified, or from 140 °F to 245 °F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Description > Page 3371 Temperature Gauge: Description and Operation Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is between the low end of normal [about 54 °C (130 °F) for gasoline engines, or about 60 °C (140 °F) for diesel engines] and the high end of normal [about 122 °C (252 °F) for gasoline engines, or about 116 °C (240 °F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is below the low end of normal [about 54 °C (130 °F) for gasoline engines, or about 60 °C (140 °F) for diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating the temperature is above about 54 °C (130 °F) for gasoline engines, or about 60 ° C (140 °F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive electronic engine temperature messages from the PCM or ECM indicating the temperature is above about 122 °C (252 °F) for gasoline engines, or about 116 °C (240 °F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the temperature is below about 122 °C (252 °F) for gasoline engines, or about 116 °C (240 °F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engine) or ECM (diesel engine) continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Description Radiator: Description and Operation Description DESCRIPTION The radiator is a aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks. This radiator does not contain an internal transmission oil cooler. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Description > Page 3376 Radiator: Description and Operation Operation OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes in the radiator core to cool the engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 3377 Radiator: Testing and Inspection RADIATOR COOLANT FLOW Use the following procedure to determine if coolant is flowing through the cooling system. 1. Idle engine until operating temperature is reached. If the upper radiator hose is warm to the touch, the thermostat is opening and coolant is flowing to the radiator. WARNING: Hot, pressurized coolant can cause injury by scalding. Using a rag to cover the radiator pressure cap, open radiator cap slowly to the first stop. This will allow any built-up pressure to vent to the reserve/overflow tank. After pressure build-up has been released, remove cap from filler neck. 2. Drain a small amount of coolant from the radiator until the ends of the radiator tubes are visible through the filler neck. Idle the engine at normal operating temperature. If coolant is flowing past the exposed tubes, the coolant is circulating. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures Radiator: Procedures Cleaning CLEANING Clean radiator fins are necessary for good heat transfer. The radiator and oil cooler fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or oil coolers of debris. Inspection INSPECTION Inspect the radiator side tanks for cracks, and broken or missing fittings. Inspect the joint where the tanks seam up to the radiator core for signs of leakage and/or deteriorating seals. Inspect radiator core for corroded, bent or missing cooling fins. Inspect the core for bent or damaged cooling tubes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3380 Radiator: Removal and Replacement Radiator - Removal 6.7L DIESEL 1. Disconnect both battery negative cables. WARNING: Do not remove the cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur. 2. Drain the cooling system See: Service and Repair . 3. Disconnect ambient air temperature sensor electrical connector and mass airflow sensor electrical connector (If equipped). 4. Remove air box and turbocharger inlet tube See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Removal . 5. Remove coolant tank hose, washer bottle hose and the positive battery cable from the fastening clips located on top of the radiator. 6. Remove hose clamps and hoses from radiator. 7. Remove fan shroud mounting nuts from mounting brackets. 8. Pull shroud toward front of vehicle to clear mounting brackets 9. Turn shroud slightly and push toward engine to gain clearance for radiator. 10. Remove the power steering cooler mounting bolts and position the power steering cooler out of the way. 11. Disconnect the transmission cooler lines at the transmission cooler See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Cooler/Service and Repair/Procedures . The transmission cooler will remain on the radiator and can be removed as an assembly. 12. Remove the two radiator upper mounting bolts. 13. Tilt radiator toward front of vehicle and lift out of engine compartment. The bottom of the radiator is equipped with two alignment dowels that fit into holes in the lower radiator support panel. Rubber biscuits (insulators) are installed to these dowels. Take care not to damage cooling fins or tubes on the radiator and air conditioning condenser or the electronic viscous fan connector when removing. Radiator - Installation 6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3381 1. Install rubber insulators to alignment dowels at lower part of radiator. 2. Lower the radiator into position while guiding the two alignment dowels into lower radiator support. Different alignment holes are provided in the lower radiator support for each engine application. 3. Install two upper radiator mounting bolts. Tighten bolts to 12 Nm (105 in. lbs.) torque. 4. Connect both radiator hoses and install hose clamps. 5. If equipped, connect transmission cooler lines to transmission cooler. Inspect quick connect fittings for debris and install until an audible "click" is heard. Tug on lines to verify connection See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Cooler/Service and Repair/Procedures . 6. Position power steering cooler on the radiator and tighten nuts to 10 Nm (90 in. lbs.) 7. Position fan shroud on brackets. 8. Install fan shroud mounting nut. Tighten nut to 24 Nm (18 ft. lbs.). 9. Install the coolant recovery container See: Coolant Reservoir/Service and Repair/Coolant Recovery Container - Installation . 10. Position coolant recovery tank hose, washer bottle hose See: Coolant Reservoir/Service and Repair/Coolant Recovery Container - Installation and the positive battery cable into the clips located on the top of the radiator. 11. Install air box and turbocharger inlet hose See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Installation . Tighten clamps to 4 Nm (35 in. lbs.). 12. Connect mass airflow sensor electrical connector and ambient air temp sensor electrical connector (if equipped). 13. Position heater controls to full heat position. 14. Fill cooling system with coolant See: Service and Repair . 15. Operate engine until it reaches normal temperature. Check cooling system and automatic transmission (if equipped) fluid levels. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description Radiator Cap: Description and Operation Description DESCRIPTION All cooling systems are equipped with a pressure cap. For all engines, the pressure cap is located on top of the radiator outlet tank. The cap releases pressure at some point within a range of 97-to-124 kPa (14-to-18 psi). The pressure relief point (in pounds) is engraved on top of the cap The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve. This valve opens when system pressure reaches the release range of 97-to-124 kPa (14-to-18 psi). A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Description > Page 3386 Radiator Cap: Description and Operation Operation OPERATION A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow container to be drawn through the recovery hose connecting the filler neck and reserve/overflow container. If the vacuum valve is stuck shut, or the recovery hose is kinked, radiator hoses will collapse on cool down. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap Radiator Cap: Testing and Inspection Radiator Cap RADIATOR CAP Remove the cap from the radiator. Be sure that the sealing surfaces are clean. Moisten the rubber gasket with water and install the cap on the pressure tester 7700 or an equivalent. Operate the tester pump to bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace the cap. CAUTION. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on the radiator. If so, inspect the radiator filler neck and radiator cap's top gasket for damage. Also inspect for dirt or distortion that may prevent the cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap > Page 3389 Radiator Cap: Testing and Inspection Radiator Cap To Filler Neck Seal RADIATOR CAP-TO-FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from the radiator filler neck tube. Attach the hose of the pressure tester tool 7700 (or equivalent) to the tube. It will be necessary to disconnect hose from its adapter for the filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69 to 124kPa (10 to 18 psi) and hold pressure at a minimum of 55 kPa (8 psi). WARNING: The warning words, "DO NOT OPEN HOT", on radiator pressure cap, are a safety precaution. When hot, pressure builds up in cooling system. To prevent scalding or injury, radiator cap should not be removed while system is hot and/or under pressure. Do not remove the radiator cap at any time except for the following purposes: - Check and adjust antifreeze freeze point. - Refill the system with new antifreeze. - Conducting service procedures. - Checking for vacuum leaks. WARNING: If vehicle has been run recently, wait at least 15 minutes before removing radiator cap. With a rag, squeeze radiator upper hose to check if system is under pressure. Place a rag over cap and without pushing cap down, rotate it counter-clockwise to first stop. Allow fluid to escape through the coolant reserve/overflow hose into reserve/overflow tank. Squeeze radiator upper hose to determine when pressure has been released. When coolant and steam stop being pushed into tank and system pressure drops, remove radiator cap completely. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Cleaning Radiator Cap: Service and Repair Cleaning CLEANING Use only a mild soap and water to clean the radiator cap. Using any type of solvent may cause damage to the seal in the radiator cap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Cleaning > Page 3392 Radiator Cap: Service and Repair Inspection INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should closed. A slight downward pull on the vent valve should open it. If the rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Component ID: 83 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Circuit Description 1 K160 18BR/OR PWM FAN COIL SIGNAL Pin Circuit Description 1 K971 18BR/PK SENSOR GROUND 2 N210 18DB/DG FAN SPEED SENSOR SIGNAL 2 K916 18BR/OR SENSOR GROUND 3 K161 18BR/LB FAN SPEED SENSOR GROUND 3 N27 18DB/GY FAN SPEED SENSOR SIGNAL 4-5 K668 18BR 5 VOLT SUPPLY 5 F855 18PK/YL 5 VOLT SUPPLY 6 A212 18PK/YL FUSED B(+) 6 K161 18BR/LB FAN SPEED SENSOR GROUND Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3397 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3398 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3399 Radiator Cooling Fan Control Module: Diagrams Component ID: 83 Component : DRIVE-FAN-RADIATOR Connector: Name : DRIVE-FAN-RADIATOR Color : DK. GRAY # of pins : 6 Qualifier : (DIESEL) Gender : FEMALE Pin Circuit Description 1 K160 18BR/OR PWM FAN COIL SIGNAL Pin Circuit Description 1 K971 18BR/PK SENSOR GROUND 2 N210 18DB/DG FAN SPEED SENSOR SIGNAL 2 K916 18BR/OR SENSOR GROUND 3 K161 18BR/LB FAN SPEED SENSOR GROUND 3 N27 18DB/GY FAN SPEED SENSOR SIGNAL 4-5 K668 18BR 5 VOLT SUPPLY 5 F855 18PK/YL 5 VOLT SUPPLY 6 A212 18PK/YL FUSED B(+) 6 K161 18BR/LB FAN SPEED SENSOR GROUND Component Location - 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3400 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 3401 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3407 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3408 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3409 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3410 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3411 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3412 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3413 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3414 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3415 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3416 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3417 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3418 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3419 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Description Temperature Gauge: Description and Operation Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines. On vehicles with a diesel engine, the scale reads from 60 °C to 120 °C in markets where a metric instrument cluster is specified, or from 140 °F to 245 °F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Description > Page 3424 Temperature Gauge: Description and Operation Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is between the low end of normal [about 54 °C (130 °F) for gasoline engines, or about 60 °C (140 °F) for diesel engines] and the high end of normal [about 122 °C (252 °F) for gasoline engines, or about 116 °C (240 °F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM or ECM indicating the temperature is below the low end of normal [about 54 °C (130 °F) for gasoline engines, or about 60 °C (140 °F) for diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating the temperature is above about 54 °C (130 °F) for gasoline engines, or about 60 ° C (140 °F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive electronic engine temperature messages from the PCM or ECM indicating the temperature is above about 122 °C (252 °F) for gasoline engines, or about 116 °C (240 °F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the temperature is below about 122 °C (252 °F) for gasoline engines, or about 116 °C (240 °F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled OFF and then ON again by the appropriate messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM (gasoline engine) or ECM (diesel engine) continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster turns ON the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Specification Begin to open at 85.5 - 89.4°C. (186 - 193°F ) Fully open (valve will stop moving) at 97°C (207°F Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3428 Thermostat: Description and Operation DIESEL CAUTION: Do not operate an engine without a thermostat, except for servicing or testing. An engine with the thermostat removed will operate in the radiator bypass mode, causing an overheat condition. The thermostat of the diesel engine is located in the front of the cylinder head, underneath a heat shield near the thermostat housing. NOTE: The thermostat for 5.9L engine and the 6.7L are different and are not interchangeable. Use caution when replacing the thermostat to ensure the proper part number is reinstalled. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat will cause overheating. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat Thermostat: Testing and Inspection Thermostat DIAGNOSIS AND TESTING ON-BOARD DIAGNOSTICS All models are equipped with On-Board Diagnostics for certain cooling system components. If the powertrain control module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or by poor heater performance unless a DTC is present. The DTC can also be accessed through the scan tool. DIESEL ENGINE The cooling system used with the diesel engine provides the extra coolant capacity and extra cooling protection needed for higher GVWR (Gross Vehicle Weight Rating) and GCWR (Gross Combined Weight Rating) vehicles. This system capacity will not affect warm up or cold weather operating characteristics if the thermostat is operating properly. This is because coolant will be held in the engine until it reaches the thermostat "set" temperature. Diesel engines, due to their inherent efficiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded. Because of this, lower temperature gauge readings for diesel versus gasoline engines may, at times be normal. Typically, complaints of low engine coolant temperature are observed as low heater output when combined with cool or cold outside temperatures. To help promote faster engine warm-up, the electric engine block heater must be used with cool or cold outside temperatures. This will help keep the engine coolant warm when the vehicle is parked. A "Cold Weather Cover" is available from the parts department through the Mopar Accessories product line. This accessory cover is designed to block airflow entering the radiator and engine compartment to promote faster engine warm-up. It attaches to the front of the vehicle at the grill opening. The cover is to be used with cool or cold temperatures only. If used with high outside temperatures, serious engine damage could result. For engines equipped with exhaust brakes, this device can be used to aid engine warm-up while the engine is idling. 1. To determine if the thermostat is defective, it must be removed from the vehicle See: Service and Repair/Engine Coolant Thermostat - Removal . 2. After the thermostat has been removed, examine the thermostat and inside of thermostat housing for contaminants. If contaminants are found, the thermostat may already be in a "stuck open" position. Flush the cooling system before replacing thermostat See: Service and Repair . 3. Place the thermostat into a container filled with water. 4. Place the container on a hot plate or other suitable heating device. 5. Place a commercially available radiator thermometer into the water. 6. Apply heat to the water while observing the thermostat and thermometer. 7. The thermostat will begin to open at 85.5 - 89.4°C. (186 - 193°F ). If the valve starts to move before this temperature is reached, it is opening too early. Replace thermostat. The thermostat should be fully open (valve will stop moving) at 97°C (207°F). If the valve is still moving when the water temperature reaches 97°C (207°F), it is opening too late. Replace thermostat. If the valve refuses to move at any time, replace thermostat. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat > Page 3431 Thermostat: Testing and Inspection Diesel Engine DIESEL ENGINE The cooling system used with the diesel engine provides the extra coolant capacity and extra cooling protection needed for higher GVWR (Gross Vehicle Weight Rating) and GCWR (Gross Combined Weight Rating) vehicles. This system capacity will not affect warm up or cold weather operating characteristics if the thermostat is operating properly. This is because coolant will be held in the engine until it reaches the thermostat "set" temperature. Diesel engines, due to their inherent efficiency are slower to warm up than gasoline powered engines, and will operate at lower temperatures when the vehicle is unloaded. Because of this, lower temperature gauge readings for diesel versus gasoline engines may, at times be normal. Typically, complaints of low engine coolant temperature are observed as low heater output when combined with cool or cold outside temperatures. To help promote faster engine warm-up, the electric engine block heater must be used with cool or cold outside temperatures. This will help keep the engine coolant warm when the vehicle is parked. A "Cold Weather Cover" is available from the parts department through the Mopar Accessories product line. This accessory cover is designed to block airflow entering the radiator and engine compartment to promote faster engine warm-up. It attaches to the front of the vehicle at the grill opening. The cover is to be used with cool or cold temperatures only. If used with high outside temperatures, serious engine damage could result. For engines equipped with exhaust brakes, this device can be used to aid engine warm-up while the engine is idling. 1. To determine if the thermostat is defective, it must be removed from the vehicle See: Service and Repair/Engine Coolant Thermostat - Removal . 2. After the thermostat has been removed, examine the thermostat and inside of thermostat housing for contaminants. If contaminants are found, the thermostat may already be in a "stuck open" position. Flush the cooling system before replacing thermostat See: Service and Repair . 3. Place the thermostat into a container filled with water. 4. Place the container on a hot plate or other suitable heating device. 5. Place a commercially available radiator thermometer into the water. 6. Apply heat to the water while observing the thermostat and thermometer. 7. The thermostat will begin to open at 85.5 - 89.4°C. (186 - 193°F ). If the valve starts to move before this temperature is reached, it is opening too early. Replace thermostat. The thermostat should be fully open (valve will stop moving) at 97°C (207°F). If the valve is still moving when the water temperature reaches 97°C (207°F), it is opening too late. Replace thermostat. If the valve refuses to move at any time, replace thermostat. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal Thermostat: Service and Repair Engine Coolant Thermostat - Removal 6.7L DIESEL ENGINE WARNING: Do not loosen the radiator draincock with the system hot and pressurized. Serious burns from the coolant can occur. 1. Disconnect the battery negative cables. 2. Remove vent plug near EGR cooler. 3. Drain cooling system until coolant level is below thermostat See: Service and Repair . 4. Disconnect exhaust gas pressure sensor electrical connector (3). 5. Remove exhaust pressure tube (4) from thermostat housing. 6. Remove EGR cooler cross over tube (1). 7. Remove radiator hose clamp and hose from thermostat housing (1). 8. Remove heat shield. 9. Remove the three water outlet-to-cylinder head bolts (5) and remove the water outlet connector. 10. Clean the mating surfaces of the thermostat housing (1) and clean the thermostat seat groove at the top of the thermostat housing (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal > Page 3434 Thermostat: Service and Repair Engine Coolant Thermostat - Installation 6.7L DIESEL ENGINE NOTE: The thermostat for 5.9L engine and the 6.7L are different and are not interchangeable. Use caution when replacing the thermostat to ensure the proper part number is reinstalled. 1. Inspect thermostat seal for cuts or nicks. Replace if damaged. 2. Install the thermostat into the groove in the top of the cylinder head. 3. Install the thermostat housing and bolts (5). Tighten the bolts to 10 Nm (89 in. lbs.). 4. Install heat shield. Tighten bolts to 9 Nm (79 in. lbs.). 5. Install exhaust pressure tube (4). Tighten to 10 Nm (88 in. lbs.). 6. Connect exhaust pressure sensor electrical connector (2). 7. Install EGR cross over tube (1). 8. Install P-clip and bolt. Tighten to 8 Nm (70 in. lbs.). 9. Install the radiator upper hose and clamp. 10. Fill the cooling system with coolant See: Service and Repair . 11. Connect the battery negative cables. 12. Start the engine and check for coolant leaks. Run engine to check for proper thermostat operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Tighten mounting bolts to 24 Nm (18 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Description Water Pump: Description and Operation Description Water Pump WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary. Water Pump Bypass WATER PUMP BYPASS The 3.7L and 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Description > Page 3440 engine warm-up preventing the coolant from flowing through the radiator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Description > Page 3441 Water Pump: Description and Operation Operation Water Pump WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Water Pump Bypass - 3.7L/4.7L WATER PUMP BYPASS - 3.7L/4.7L When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the pill partially covers the bypass hole, reducing the amount of bypass flow. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Page 3442 Water Pump: Testing and Inspection WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Cleaning CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. Inspection INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 3445 Water Pump: Removal and Replacement Water Pump - Removal 6.7L DIESEL 1. Disconnect battery negative cables. 2. Drain cooling system See: Service and Repair . 3. Disconnect ambient air temp sensor electrical connector and mass airflow sensor electrical connector (if equipped). 4. Remove turbocharger inlet tube and air filter housing. For 5.9L Diesel, See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Removal, for 6.7L Diesel, See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing Removal . 5. Remove generator assembly See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator - Removal . 6. Remove the accessory drive belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Removal . 7. Remove water pump mounting bolts (3). 8. Remove O-ring from water pump. 9. Clean water pump sealing surface on cylinder block. Water Pump - Installation 6.7L DIESEL 1. Install new O-ring seal in groove on water pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 3446 2. Install water pump with the weep hole facing downward. Tighten mounting bolts to 24 Nm (18 ft. lbs.) torque. 3. Install generator assembly. 4. Install accessory drive belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Accessory Drive Belt - Installation . 5. Install air box and tube assembly. For 5.9L Diesel, See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Installation . For 6.7L Diesel, See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Installation . 6. Install air filter housing See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Housing Installation . 7. Fill cooling system See: Service and Repair . 8. Connect both battery cables. 9. Start and warm the engine. Check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3453 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3454 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3455 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3456 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3457 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3458 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3459 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3460 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3463 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3464 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3465 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3466 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3467 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3468 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3469 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3470 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 3473 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3476 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). PRESSURE DIFFERENTIAL TUBING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 3483 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 3484 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION PRESSURE DIFFERENTIAL TUBING 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 3485 NOTE: Make sure there is not a dip in the pressure differential hoses. 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): Customer Interest Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3494 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3495 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): All Technical Service Bulletins Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3501 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 3502 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description Diesel Particle Filter (DPF): Description and Operation Description DESCRIPTION DIESEL OXIDATION CATALYST (DOC) The Diesel Oxidation Catalyst (DOC) is a ceramic flow through substrate coated with a catalyst washcoat that is integral to the DOC assembly. The close coupled DOC treats engine exhaust gases by converting harmful carbon monoxide, unburned hydrocarbons and other compounds into water, carbon dioxide and heat. Pick-up vehicles use a separate DOC assembly. Cab-Chassis vehicles use a combination Diesel Oxidation Catalyst/Diesel Particulate Filter (DOC/DPF) DIESEL PARTICULATE FILTER The Diesel Particulate Filter (DPF) is a wall-pass ceramic filter substrate coated with a catalyst washcoat that is integral to the DOC/DPF assembly. The partially treated exhaust gases from the DOC, flow into the catalyzed diesel particulate filter (DPF) which traps and accumulates particulate matter and further treats the exhaust gases to reduce unburned hydrocarbons and other harmful compounds. the trapped particulate molecules will be periodically removed from the DPF via a thermal regeneration process initiated by the engine's electronic control module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description > Page 3505 Diesel Particle Filter (DPF): Description and Operation Operation OPERATION The oxidation catalyst raises the exhaust gas temperatures to regenerate the DPF, which is passive regeneration. If the passive regeneration cannot keep up with the build up of soot in the DPF, the ECM will actively regenerate the DPF to burn off the soot. Residue remains inside the DPF in the form of non burnable ash. Ash comes from the oils and other materials that are trapped in the oils and are present in the soot. The catalyst contains a large number of parallel channels, which run in the axial direction and are separated by thin porous walls. The channels are alternatively open at one end, but plugged at the other. The exhaust gases flow through the walls and escape through the pores in the wall material. Particulates, however, are too large to escape and are trapped in the monolith walls. The ECM starts the regeneration of the DPF if the soot load exceeds a performance map value. The ECM determines the load condition of the DPF based upon the exhaust gas pressure upstream and downstream of the DPC/DPF. A pressure differential sensor provides the pressure input to the ECM. During the regeneration process, the ECM raises the temperature in the DOC/DPF to burn off the soot accumulated. Under normal operation, the engine does not produce enough heat to oxidize the soot inside the DOC/DPF. This process requires temperatures above 550°C (1,022°F). After regeneration, the ECM reads the actual pressure difference at the DOC/DPF and compares it with a reference value. From this comparison, the ECM determines the ash quantity inside the DOC/DPF. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Page 3506 Diesel Particle Filter (DPF): Testing and Inspection DIESEL PARTICULATE FILTER EVIC Message Center - Message - Catalyst Full The engine Electronic Control Module (ECM) monitors the soot load in the diesel particulate filter. Under normal operating conditions the diesel particulate filter is self-cleaning, where accumulated soot is converted to ash. Under light load operating conditions, the driver may be notified via the vehicle's Electronic Vehicle Information Center (EVIC) message center "CATALYST FULL: SEE OWNERS MAN" message will be displayed indicating that it is necessary to modify the vehicles driving routine/duty-cycle in order to allow the diesel particulate filter system to self clean. If the vehicle's EVIC message center notification is ignored, the vehicle will eventually derate the engine and set a fault, requiring service. The soot load in the diesel particulate filter is estimated by the ECM using the Exhaust Pressure Sensor values and the calculated soot output of the engine. This fault code will be triggered if the application is not operating at a duty cycle high enough to allow active regeneration of the diesel particulate filter. This fault code is an indication that the exhaust temperatures exiting the turbocharger are not high enough to allow active regeneration of the soot that is trapped in the diesel particulate filter. It may be necessary to increase the duty cycle of the application in order to prevent excessive soot accumulation and plugging of the diesel particulate filter. The ECM will set this fault if it detects that the soot level has exceeded the normal desoot trigger threshold by a sufficient amount to indicate that the driver intervention is required. There is not a MIL lamp associated with this fault code, though the driver will be notified via the EVIC message. Have owner drive vehicle at highway speeds (50/60 mph) for a minimum of 45 minutes. If the message CATALYST FULL SERVICE REQ'D. is still displayed, Refer to appropriate testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis Diesel Particle Filter (DPF): Service and Repair Removal - Cab Chassis 6.7L DIESEL - CAB CHASSIS WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove flexible tubing from particulate filter pressure sensor tubing. 4. Loosen and remove particulate filter pressure sensor tubing from Diesel Oxidation Catalytic/Diesel Particulate Filter (DOC/DPF). 5. Disconnect and remove temperature sensors. 6. 4X4 Vehicles Remove transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Removal . 7. 4X4 Vehicles - Remove transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal . 8. Remove exhaust pipe to DOC/DPF flange nuts (5) 9. Remove intermediate pipe to DOC/PDF clamp nuts (2). 10. Move muffler and tail pipe assembly (1) toward rear of vehicle. 11. Remove DOC/DPF (4). 12. Remove and discard flange gaskets. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 3509 Diesel Particle Filter (DPF): Service and Repair Removal - P/U REMOVAL CATALYTIC CONVERTER 6.7L - DIESEL - P/U 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect flexible exhaust differential pressure sensor tubing (2). 4. Remove exhaust pressure differential sensor tubing from Diesel Particulate Filter (DPF) (1). 5. 4X4 Vehicles - Remove transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Removal . 6. 4X4 Vehicles - Remove transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal . 7. Remove Diesel Particulate Filter (DPF) to NOx Absorber Catalyst (NAC) flange nuts (7). 8. Remove NAC to Diesel Oxidation Catalyst (DOC) to NAC flange nuts (5). Discard gasket. 9. Remove NAC (7) from isolators. 10. Remove DOC to muffler band clamp. 11. Remove DOC from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 3510 Diesel Particle Filter (DPF): Service and Repair Installation - Cab Chassis 6.7L DIESEL - CAB CHASSIS 1. Position new exhaust flange gaskets on exhaust pipe (6) to DOC/DPF flange and DOC/DPF into intermediate pipe (1). 2. Using new gasket, position the DOC/DPF (4) onto the front exhaust pipe flange. 3. Install flange nuts (5). Hand tighten only. 4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Tighten flange nuts (5) to 54 Nm (40 ft. lbs) 6. Tighten band clamp nuts to 52 Nm (40 ft. lbs.) 7. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 8. Install exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) NOTE: Make sure there is not a dip in the pressure differential tubing. 9. Install flexible exhaust differential pressure sensor tubing. 10. 4X4 Vehicles - Install transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation . 11. 4X4 Vehicles Install transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Installation . 12. Connect electrical connectors. 13. Connect negative battery cable. 14. Using scan tool, under ENGINE MISC. FUNCTIONS, perform DIESEL PARTICULATE FILTER REPLACEMENT function. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 3511 Diesel Particle Filter (DPF): Service and Repair Installation - P/U 6.7L DIESEL - P/U CATALYTIC CONVERTER 6.7L - DIESEL - P/U 1. Position DOC onto muffler. Install band clamp and tighten to 54 Nm (40 ft. lbs.). 2. Using new gaskets position NAC (6) onto the DOC (4) and Diesel Particulate Filter (DPF). 3. Install DOC to NAC flange nuts. Tighten nuts to 54 Nm (40 ft. lbs.). 4. Install differential pressure tube support into DPF. Tighten tubing nuts to Tighten fittings to 30 Nm (22 ft. lbs.). NOTE: Make sure there is not a dip in the pressure differential hoses. 5. Install flexible differential pressure tubing (2). 6. 4X4 Vehicles - Install transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation . 7. 4X4 Vehicles - Install transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Installation . 8. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 9. Lower the vehicle. 10. Connect negative battery cable (s). 11. Using scan tool, under ENGINE MISC. FUNCTIONS, perform DIESEL PARTICULATE FILTER REPLACEMENT function. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations Exhaust Brake Switch: Locations Component ID: 488 Component : SWITCH-EXHAUST BRAKE Connector: Name : SWITCH-EXHAUST BRAKE Color : # of pins : 6 Qualifier : (6.7L) Pin Circuit Description 1 Z933 20BK/BR GROUND 2 E11 20OR/DB PANEL LAMPS DRIVER 3 G905 20BR/OR EXHAUST BRAKE SWITCH SIGNAL 4 V937 20VT/BR S/C SWITCH RETURN 5 G904 20VT/DG EXHAUST BRAKE LAMP SIGNAL 6-- Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations > Page 3516 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations > Page 3517 Exhaust Brake Switch: Diagrams Component ID: 488 Component : SWITCH-EXHAUST BRAKE Connector: Name : SWITCH-EXHAUST BRAKE Color : # of pins : 6 Qualifier : (6.7L) Pin Circuit Description 1 Z933 20BK/BR GROUND 2 E11 20OR/DB PANEL LAMPS DRIVER 3 G905 20BR/OR EXHAUST BRAKE SWITCH SIGNAL 4 V937 20VT/BR S/C SWITCH RETURN 5 G904 20VT/DG EXHAUST BRAKE LAMP SIGNAL 6-- Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Brake > Exhaust Brake Switch > Component Information > Locations > Page 3518 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Starting from the center and moving in a pattern outward, torque the exhaust manifold bolts to 43 N.m (32 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures Exhaust Manifold: Procedures Exhaust Manifold - Cleaning CLEANING Clean the cylinder head and exhaust manifold sealing surfaces with a suitable scraper. Use a Scotch-Brite(TM) pad or equivalent. Exhaust Manifold - Inspection INSPECTION Inspect the exhaust manifold for cracks. Measure the exhaust manifold for flatness. Place a ruler over all of the exhaust ports and insert a feeler gauge between the port flange and the ruler. Maximum deviation from flat is 0.20 mm (.008 inch). Inspection of turbocharger mounting flange: Using a straight edge across the longest sections of the flange, measure the flatness using a feeler gauge. Warpage shall not exceed 0.1mm (0.0039 in). When measuring the exhaust manifold flanges, the total sum of exhaust flange and the turbocharger flange cannot exceed 0.1 mm (0.00039 in). If this is the case, the component with the greatest warpage must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 3524 Exhaust Manifold: Removal and Replacement Exhaust Manifold - Removal REMOVAL 1. Disconnect the battery negative cables. 2. Drain the coolant. See: Cooling System/Service and Repair 3. Raise vehicle on hoist. 4. Remove the EGR cooler. See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Removal and Replacement 5. Remove the air filter housing. See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair 6. Remove the air filter inlet hose from the turbo inlet. 7. Remove the delta-P line bracket capscrew nuts and remove the delta-P line from the exhaust manifold and thermostat housing. 8. Remove the heat shield and noise panel (if equipped) from the exhaust manifold. 9. Remove the turbocharger. See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Removal and Replacement 10. Remove the two (2) rear exhaust manifold capscrew lock plates. 11. Remove the Cab Heater tubing/bracket from the exhaust manifold stud. 12. Remove the exhaust manifold. Exhaust Manifold - Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 3525 1. Clean the exhaust manifold gasket surfaces. 2. Clean the cylinder head exhaust port gasket surfaces. 3. Clean the turbo mounting flange on the exhaust manifold. 4. Clean the turbo mounting flange on the turbocharger. 5. Install the exhaust manifold to turbocharger gasket and capscrews. 6. Install the exhaust manifold gasket. NOTE:The five exhaust manifold capscrews with studs are used at the No.1 and No.2 cylinder locations for the heat shield mounting and one on the rear lower corner of the manifold for the cabin heater tube bracket. 7. Install the exhaust manifold spacers and capscrews. 8. Starting from the center and moving in a pattern outward, tighten the exhaust manifold bolts to 43 N-m (32 ft. lbs.) 9. Install the exhaust manifold capscrew lock plates. 10. Install the exhaust manifold heat shields/noise panels. Tighten the mounting nuts to 24 N-m (18 ft. lbs.). 11. Install the turbocharger. See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Removal and Replacement 12. Attach the mounting tabs and start the delta-P tube to exhaust manifold and thermostat capscrews. 13. Tighten the delta-P line bracket nut to 24 N-m (18 ft. lbs.). 14. Tighten the delta-P line bracket bolt to 10 N-m (89 in. lbs.). 15. Tighten the delta-P flare nuts to 10 N-m (89 in. lbs.). 16. Install the EGR cooler. See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Removal and Replacement 17. Install the air filter housing. See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair 18. Fill the coolant. See: Cooling System/Service and Repair 19. Connect the battery negative cables. 20. Start the engine to check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal Exhaust Pipe: Service and Repair Exhaust Pipe - Removal 6.7L DIESEL - CAB CHASSIS 1. Raise and support the vehicle on a hoist. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove the exhaust pipe-to-DOC/DPF flange nuts (2). 4. 4X4 Vehicles - Remove transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Removal . 5. 4X4 Vehicles - Remove transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal . 6. Remove the exhaust pipe-to-turbocharger clamp (5) and discard. 7. Remove the transmission mounted exhaust pipe support (4). 8. Separate the exhaust pipe (3). 9. Remove exhaust pipe (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 3530 Exhaust Pipe: Service and Repair Exhaust Pipe - Inspection INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 3531 Exhaust Pipe: Service and Repair Exhaust Pipe - Installation 6.7L DIESEL 1. Using a new flange gasket, position exhaust pipe (3) on DOC/DPF flange and turbocharger flange. 2. Install flange nuts (2). Tighten nuts (2) to 54 Nm (40 ft. lbs.) 3. Install a new exhaust pipe-to-turbocharger clamp (5). Do not tighten clamp at this time. 4. Install transmission mounted exhaust pipe support (4). Tighten bolts to 43 Nm (32 ft. lbs.). 5. 4X4 Vehicles - Install transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember Installation . 6. 4X4 Vehicles - Install transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Installation . 7. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 8. Tighten turbocharger clamp nut to 16 Nm (150 in. lbs.). 9. Lower the vehicle. 10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 3532 Exhaust Pipe: Service and Repair Tailpipe Removal DIESEL 1. Disconnect the battery negative cables. 2. Raise and support the vehicle. 3. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 4. Disconnect the exhaust tailpipe support hanger isolators. 5. Remove the muffler-to-tailpipe clamps. 6. Remove the tailpipe from the vehicle. Inspection INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. Installation DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe - Removal > Page 3533 1. Install the tailpipe into the muffler. 2. Install the tailpipe hanger rods into the isolators 3. Install the exhaust clamp, align the exhaust system, and tighten the clamp 48 Nm (35 ft. lbs.) torque. 4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Lower the vehicle. 6. Connect the battery negative cables. 7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3538 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3539 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3540 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3541 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3542 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3543 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3546 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3547 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3548 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3549 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3550 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3551 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation Heat Shield: Description and Operation DESCRIPTION There are two types of heat shields used. One is stamped steel the other is molded foil sheets. The shields attach to the vehicle around the exhaust system to prevent heat from the exhaust system from entering the passenger area and other areas where the heat can cause damage to other components. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal Heat Shield: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts or bolts holding the exhaust heat shield to the floor pan, crossmember or bracket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 3557 3. Slide the shield out around the exhaust system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 3558 Heat Shield: Service and Repair Installation INSTALLATION 1. Position the exhaust heat shield to the floor pan, crossmember or bracket and install the nuts or bolts. 2. Tighten the nuts and bolts 11 Nm (100 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 3559 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal Muffler: Service and Repair Removal DIESEL 1. Disconnect the battery negative cables. 2. Raise and support the vehicle. 3. Remove the muffler to tail pipe and extension pipe clamps. 4. Disconnect the muffler from the hanger isolators. 5. Disconnect the muffler from the tailpipe. 6. Disconnect the muffler from the extension pipe and remove from the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 3564 Muffler: Service and Repair Installation DIESEL 1. Install the muffler hanger rods into the isolators. 2. Install the muffler into the extension pipe. 3. Install the muffler into the tail pipe. 4. Install the exhaust clamps, align the exhaust system, and tighten the exhaust clamps to 54 Nm (40 ft. lbs.). 5. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 6. Insure isolators are fully seated on exhaust hangers. 7. Lower the vehicle. 8. Connect the battery negative cables. 9. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3570 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3571 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3572 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3573 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3574 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 3575 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3578 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3579 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3580 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3581 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3582 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 3583 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3588 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3589 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3590 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3591 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3592 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3593 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3594 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 3595 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3598 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3599 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3600 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3601 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3602 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3603 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3604 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 3605 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 3608 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3611 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3619 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3620 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3621 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3622 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3625 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3628 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3629 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3630 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3631 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3633 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3634 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3643 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3644 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3645 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3646 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3647 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3648 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3649 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3655 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3656 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3657 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3658 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3664 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3665 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3666 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3667 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3672 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3673 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3674 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3675 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3676 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3677 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3678 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3684 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3685 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3686 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 3687 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3693 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3694 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3695 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3696 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3697 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3698 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 3699 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 205 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Circuit Description 1 K139 18DB WASTEGATE SOLENOID CONTROL 2 G6 18VT/GY OIL PRESSURE SIGNAL 3-4 D65 18WT/LG CAN C BUS (+) 5 D64 18WT/LB CAN C BUS (-) 6 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 7 K20 18BR/GY GEN FIELD CONTROL 8 K314 18TN/YL TTVA MOTOR (+) 9-10 - 11 K923 18BR/WT WATER IN FUEL SENSOR GROUND 12 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 13 K615 18VT/WT INLET AIR TEMPERATURE SENSE 14 - 15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 K616 18BR/YL INLET AIR PRESSURE SENSE 17 K2 18VT/OR ECT SIGNAL 18 - 19 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER 20 K315 18TN/OR TTVA MOTOR (-) 21 K161 18BR/LB FAN SPEED SENSOR GROUND 22 K24 18BR/LB CKP SIGNAL 23 K200 18BR/YL SENSOR GROUND 24 K44 18DB/GY CMP SIGNAL 25 K668 18BR 5 VOLT SUPPLY 26 - 27 K853 18DB/BR 5 VOLT SUPPLY 28 - 29 K690 18BR/YL SENSOR GROUND 30 K11 16BR/YL INJECTOR CONTROL NO. 1 31 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 32 K944 18BK/GY CMP SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3702 33 K167 18BR/YL APPS NO. 1 RETURN 34 N210 18DB/DG FAN SPEED SENSOR SIGNAL 35 - 36 K14 16BR/TN INJECTOR CONTROL NO. 4 37 - 38 - 39 - 40 K13 16TN INJECTOR CONTROL NO. 3 41 K210 18DB/TN SENSOR GROUND 42 K852 18BR/VT 5 VOLT SUPPLY 43 K37 18LB BOOST PRESSURE SENSOR SIGNAL 44 - 45 - 46 K58 16BR/VT INJECTOR CONTROL NO. 6 47 - 48 - 49 - 50 K12 16BR/DB INJECTOR CONTROL NO. 2 51 - 52 K975 18BR/OR CKP SENSOR GROUND 53 K915 18BR/WT FUEL RAIL SENSOR RETURN 54 F855 18PK/YL 5 VOLT SUPPLY 55 - 56 K38 16GY INJECTOR CONTROL NO. 5 57 K229 16TN/PK INJECTOR HIGH SIDE DRIVER-BANK 2 58 - 59 K227 16BR/LG INJECTOR HIGH SIDE DRIVER-BANK 1 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3703 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3704 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3705 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K682 18DB/WT EGR CONTROL NO. 1 3 K684 18DB/YL EGR CONTROL NO. 2 4 K686 18GY/DB EGR CONTROL NO. 3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3706 5 K685 18DB EGR SIGNAL NO. 2 6-7 K161 18BR/LB FAN SPEED SENSOR GROUND 8-9 K670 18BR/LB EGR BYPASS VALVE SIGNAL 10 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN 11 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 12 - 13 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 14 K926 18DB/GY CRANKCASE SENSOR SIGNAL 15 K2 18VT/OR ECT SIGNAL 16 - 17 K671 18BR/DB EGR BYPASS STATUS 18 N27 18DB/GY FAN SPEED SENSOR SIGNAL 19 K37 18BR BOOST PRESSURE SENSOR SIGNAL 20 K616 18BR/YL INLET AIR PRESSURE SENSE 21 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 22 K971 18BR/PK SENSOR GROUND 23 - 24 K615 18VT/WT INLET AIR TEMPERATURE SENSE 25 K683 18DB/GY EGR SIGNAL NO. 1 26 K824 18DB/BR 5 VOLT SUPPLY 27 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 28 A804 18RD GEN SENSE 29 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 30 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 31 K24 18BR/LB CKP SIGNAL 32 G6 18VT/GY OIL PRESSURE SIGNAL 33 K972 18DB/TN ACTUATOR GROUND 34 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 35 K687 18DB/LB EGR SIGNAL NO. 3 36 F855 18PK/YL 5 VOLT SUPPLY 37 K44 18DB/GY CMP SIGNAL 38 D130 18BR/VT ACTUATOR HIGH DATA LINK 39 D131 18WT/LG ACTUATOR LOW DATA LINK 40 K20 18BR/GY GEN FIELD CONTROL 41 K935 18DB EGR TEMPERATURE SENSOR SIGNAL 42 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 43 K541 18BR/VT TURBO SPEED SENSOR GROUND 44 K925 18BR/OR CKP SENSOR GROUND 45 K58 16BR/VT INJECTOR CONTROL NO. 6 46 K12 16BR/DB INJECTOR CONTROL NO. 2 47 K914 18BR/WT SENSOR GROUND 48 K916 18BR/OR SENSOR GROUND 49 - 50 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL 51 K613 16GY/BR INJECTOR HIGH SIDE DRIVER NO. 3 52 K612 16YL/BR INJECTOR HIGH SIDE DRIVER NO. 2 53 K611 16OR/BR INJECTOR HIGH SIDE DRIVER NO. 1 54 K14 16BR/TN INJECTOR CONTROL NO. 4 55 K38 16GY INJECTOR CONTROL NO. 5 56 K13 16TN INJECTOR CONTROL NO. 3 57 K11 16BR/YL INJECTOR CONTROL NO. 1 58 K658 16LG/BR INJECTOR HIGH SIDE DRIVER NO. 6 59 K638 16LB/BR INJECTOR HIGH SIDE DRIVER NO. 5 60 K614 16WT/BR INJECTOR HIGH SIDE DRIVER NO. 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3707 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3708 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3709 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Circuit Description 1-2-3 K23 18BR/WT APPS NO. 1 SIGNAL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3710 5 T515 18YL/DB TRANSMISSION CONTROL 6 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 7 K31 18BR FUEL PUMP CONTROL 8-9 T41 18YL/DB TRS T41 SIGNAL (P/N) 10 - 11 - 12 - 13 T6 18DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 14 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 15 T9 18DG/TN 3-4 SOLENOID CONTROL 16 - 17 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 18 - 19 - 20 A209 16RD FUSED B(+) 21 Z902 16BK GROUND 22 - 23 F856 18YL/PK 5 VOLT SUPPLY 24 K900 18DB/DG SENSOR GROUND 25 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 26 - 27 K312 18OR TTVA POSITION SENSOR SIGNAL 28 - 29 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL 30 A209 16RD FUSED B(+) 31 - 32 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 K854 18VT/BR 5 VOLT SUPPLY 34 - 35 K29 18WT/BR APPS NO. 2 SIGNAL 36 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 37 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 38 - 39 - 40 A209 16RD FUSED B(+) 41 C13 18LB/OR A/C CLUTCH CONTROL 42 - 43 K160 18BR/OR PWM FAN COIL SIGNAL 44 T14 18DG/BR OUTPUT SPEED SIGNAL 45 T13 18DG/VT SPEED SENSOR GROUND 46 V37 18VT S/C SWITCH NO. 1 SIGNAL 47 K25 18DB/VT BATT TEMP SIGNAL 48 K400 18BR/VT APPS NO. 2 RETURN 49 Z902 16BK GROUND 50 Z902 16BK GROUND Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3711 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3712 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3713 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 D65 18WT/LG CAN C BUS (+) 2 K31 18BR FUEL PUMP CONTROL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3714 5 G905 18BR/OR EXHAUST BRAKE SWITCH SIGNAL 6 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 7 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 8 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 9 K186 18BR/OR EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 10 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 11 - 12 - 13 - 14 - 15 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 16 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 17 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 18 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 19 - 20 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 21 D64 18WT/LB CAN C BUS (-) 22 K400 18BR/VT APPS NO. 2 RETURN 23 - 24 K29 18WT/BR APPS NO. 2 SIGNAL 25 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 26 K854 18VT/BR 5 VOLT SUPPLY 27 K852 18BR/LB 5 VOLT SUPPLY 28 K167 18BR/DG APPS NO. 1 RETURN 29 K900 18DB/DG SENSOR GROUND 30 K25 18DB/VT BATT TEMP SIGNAL 31 D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK 32 - 33 V937 18VT/BR S/C SWITCH RETURN 34 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 35 K23 18BR/WT APPS NO. 1 SIGNAL 36 - - 37 K128 18DG/LG REMOTE THROTTLE SIGNAL 38 - 39 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 40 V37 18VT S/C SWITCH NO. 1 SIGNAL 41 - 42 - 43 K348 18BR SMART POWER RELAY RETURN 44 C13 18LB A/C CLUTCH CONTROL 45 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 46 - 47 Z902 16BK GROUND 48 Z902 16BK GROUND 49 A209 16RD FUSED B(+) 50 A209 16RD FUSED B(+) 51 D132 18WT DIAGNOSTIC PORT LOW DATA LINK 52 - 53 - 54 G904 18VT/DG EXHAUST BRAKE LAMP SIGNAL 55 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 56 V38 18VT/OR S/C SWITCH NO. 2 SIGNAL 57 Z902 16BK GROUND 58 - 59 - 60 A209 16RD FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3715 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3716 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3717 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3718 Engine Control Module: Locations Module-Powertrain Control Component ID 198 Component ID: 198 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 12345- 6789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3719 18 - - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3720 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3721 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3722 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3723 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3724 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3725 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3726 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3727 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3728 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3729 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3730 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3731 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3732 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3733 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3734 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3735 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3736 Component ID 211 Component ID: 211 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3737 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 - 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3738 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3739 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3740 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3741 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3742 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3743 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3744 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3745 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3746 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3747 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3748 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3749 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3750 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3751 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3752 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3753 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 3754 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3757 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3758 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3759 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3760 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3761 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3762 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3763 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3764 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3765 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3766 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3767 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3768 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3769 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3770 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3771 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3772 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 Engine Control Module: Connector Views Module-Engine Control Component ID: 205 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Circuit Description 1 K139 18DB WASTEGATE SOLENOID CONTROL 2 G6 18VT/GY OIL PRESSURE SIGNAL 3-4 D65 18WT/LG CAN C BUS (+) 5 D64 18WT/LB CAN C BUS (-) 6 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 7 K20 18BR/GY GEN FIELD CONTROL 8 K314 18TN/YL TTVA MOTOR (+) 9-10 - 11 K923 18BR/WT WATER IN FUEL SENSOR GROUND 12 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 13 K615 18VT/WT INLET AIR TEMPERATURE SENSE 14 - 15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 K616 18BR/YL INLET AIR PRESSURE SENSE 17 K2 18VT/OR ECT SIGNAL 18 - 19 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER 20 K315 18TN/OR TTVA MOTOR (-) 21 K161 18BR/LB FAN SPEED SENSOR GROUND 22 K24 18BR/LB CKP SIGNAL 23 K200 18BR/YL SENSOR GROUND 24 K44 18DB/GY CMP SIGNAL 25 K668 18BR 5 VOLT SUPPLY 26 - 27 K853 18DB/BR 5 VOLT SUPPLY 28 - 29 K690 18BR/YL SENSOR GROUND 30 K11 16BR/YL INJECTOR CONTROL NO. 1 31 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 32 K944 18BK/GY CMP SENSOR GROUND 33 K167 18BR/YL APPS NO. 1 RETURN 34 N210 18DB/DG FAN SPEED SENSOR SIGNAL 35 - 36 K14 16BR/TN INJECTOR CONTROL NO. 4 37 - 38 - 39 - 40 K13 16TN INJECTOR CONTROL NO. 3 41 K210 18DB/TN SENSOR GROUND 42 K852 18BR/VT 5 VOLT SUPPLY 43 K37 18LB BOOST PRESSURE SENSOR SIGNAL 44 - 45 - 46 K58 16BR/VT INJECTOR CONTROL NO. 6 47 - 48 - 49 - 50 K12 16BR/DB INJECTOR CONTROL NO. 2 51 - 52 K975 18BR/OR CKP SENSOR GROUND 53 K915 18BR/WT FUEL RAIL SENSOR RETURN 54 F855 18PK/YL 5 VOLT SUPPLY 55 - 56 K38 16GY INJECTOR CONTROL NO. 5 57 K229 16TN/PK INJECTOR HIGH SIDE DRIVER-BANK 2 58 - 59 K227 16BR/LG INJECTOR HIGH SIDE DRIVER-BANK 1 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3777 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K682 18DB/WT EGR CONTROL NO. 1 3 K684 18DB/YL EGR CONTROL NO. 2 4 K686 18GY/DB EGR CONTROL NO. 3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3778 5 K685 18DB EGR SIGNAL NO. 2 6-7 K161 18BR/LB FAN SPEED SENSOR GROUND 8-9 K670 18BR/LB EGR BYPASS VALVE SIGNAL 10 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN 11 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 12 - 13 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 14 K926 18DB/GY CRANKCASE SENSOR SIGNAL 15 K2 18VT/OR ECT SIGNAL 16 - 17 K671 18BR/DB EGR BYPASS STATUS 18 N27 18DB/GY FAN SPEED SENSOR SIGNAL 19 K37 18BR BOOST PRESSURE SENSOR SIGNAL 20 K616 18BR/YL INLET AIR PRESSURE SENSE 21 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 22 K971 18BR/PK SENSOR GROUND 23 - 24 K615 18VT/WT INLET AIR TEMPERATURE SENSE 25 K683 18DB/GY EGR SIGNAL NO. 1 26 K824 18DB/BR 5 VOLT SUPPLY 27 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 28 A804 18RD GEN SENSE 29 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 30 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 31 K24 18BR/LB CKP SIGNAL 32 G6 18VT/GY OIL PRESSURE SIGNAL 33 K972 18DB/TN ACTUATOR GROUND 34 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 35 K687 18DB/LB EGR SIGNAL NO. 3 36 F855 18PK/YL 5 VOLT SUPPLY 37 K44 18DB/GY CMP SIGNAL 38 D130 18BR/VT ACTUATOR HIGH DATA LINK 39 D131 18WT/LG ACTUATOR LOW DATA LINK 40 K20 18BR/GY GEN FIELD CONTROL 41 K935 18DB EGR TEMPERATURE SENSOR SIGNAL 42 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 43 K541 18BR/VT TURBO SPEED SENSOR GROUND 44 K925 18BR/OR CKP SENSOR GROUND 45 K58 16BR/VT INJECTOR CONTROL NO. 6 46 K12 16BR/DB INJECTOR CONTROL NO. 2 47 K914 18BR/WT SENSOR GROUND 48 K916 18BR/OR SENSOR GROUND 49 - 50 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL 51 K613 16GY/BR INJECTOR HIGH SIDE DRIVER NO. 3 52 K612 16YL/BR INJECTOR HIGH SIDE DRIVER NO. 2 53 K611 16OR/BR INJECTOR HIGH SIDE DRIVER NO. 1 54 K14 16BR/TN INJECTOR CONTROL NO. 4 55 K38 16GY INJECTOR CONTROL NO. 5 56 K13 16TN INJECTOR CONTROL NO. 3 57 K11 16BR/YL INJECTOR CONTROL NO. 1 58 K658 16LG/BR INJECTOR HIGH SIDE DRIVER NO. 6 59 K638 16LB/BR INJECTOR HIGH SIDE DRIVER NO. 5 60 K614 16WT/BR INJECTOR HIGH SIDE DRIVER NO. 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3779 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3780 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3781 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Circuit Description 1-2-3 K23 18BR/WT APPS NO. 1 SIGNAL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3782 5 T515 18YL/DB TRANSMISSION CONTROL 6 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 7 K31 18BR FUEL PUMP CONTROL 8-9 T41 18YL/DB TRS T41 SIGNAL (P/N) 10 - 11 - 12 - 13 T6 18DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 14 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 15 T9 18DG/TN 3-4 SOLENOID CONTROL 16 - 17 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 18 - 19 - 20 A209 16RD FUSED B(+) 21 Z902 16BK GROUND 22 - 23 F856 18YL/PK 5 VOLT SUPPLY 24 K900 18DB/DG SENSOR GROUND 25 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 26 - 27 K312 18OR TTVA POSITION SENSOR SIGNAL 28 - 29 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL 30 A209 16RD FUSED B(+) 31 - 32 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 K854 18VT/BR 5 VOLT SUPPLY 34 - 35 K29 18WT/BR APPS NO. 2 SIGNAL 36 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 37 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 38 - 39 - 40 A209 16RD FUSED B(+) 41 C13 18LB/OR A/C CLUTCH CONTROL 42 - 43 K160 18BR/OR PWM FAN COIL SIGNAL 44 T14 18DG/BR OUTPUT SPEED SIGNAL 45 T13 18DG/VT SPEED SENSOR GROUND 46 V37 18VT S/C SWITCH NO. 1 SIGNAL 47 K25 18DB/VT BATT TEMP SIGNAL 48 K400 18BR/VT APPS NO. 2 RETURN 49 Z902 16BK GROUND 50 Z902 16BK GROUND Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3783 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3784 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3785 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 D65 18WT/LG CAN C BUS (+) 2 K31 18BR FUEL PUMP CONTROL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3786 5 G905 18BR/OR EXHAUST BRAKE SWITCH SIGNAL 6 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 7 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 8 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 9 K186 18BR/OR EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 10 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 11 - 12 - 13 - 14 - 15 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 16 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 17 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 18 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 19 - 20 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 21 D64 18WT/LB CAN C BUS (-) 22 K400 18BR/VT APPS NO. 2 RETURN 23 - 24 K29 18WT/BR APPS NO. 2 SIGNAL 25 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 26 K854 18VT/BR 5 VOLT SUPPLY 27 K852 18BR/LB 5 VOLT SUPPLY 28 K167 18BR/DG APPS NO. 1 RETURN 29 K900 18DB/DG SENSOR GROUND 30 K25 18DB/VT BATT TEMP SIGNAL 31 D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK 32 - 33 V937 18VT/BR S/C SWITCH RETURN 34 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 35 K23 18BR/WT APPS NO. 1 SIGNAL 36 - - 37 K128 18DG/LG REMOTE THROTTLE SIGNAL 38 - 39 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 40 V37 18VT S/C SWITCH NO. 1 SIGNAL 41 - 42 - 43 K348 18BR SMART POWER RELAY RETURN 44 C13 18LB A/C CLUTCH CONTROL 45 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 46 - 47 Z902 16BK GROUND 48 Z902 16BK GROUND 49 A209 16RD FUSED B(+) 50 A209 16RD FUSED B(+) 51 D132 18WT DIAGNOSTIC PORT LOW DATA LINK 52 - 53 - 54 G904 18VT/DG EXHAUST BRAKE LAMP SIGNAL 55 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 56 V38 18VT/OR S/C SWITCH NO. 2 SIGNAL 57 Z902 16BK GROUND 58 - 59 - 60 A209 16RD FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3787 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3788 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3789 Component ID 198 Component ID: 198 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3790 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 - 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3791 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3792 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3793 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3794 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3795 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3796 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3797 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3798 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3799 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3800 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3801 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3802 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3803 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3804 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 Component ID 211 Component ID: 211 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 - 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3824 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel Engine Control Module: Description and Operation Engine Control Module (ECM) - Diesel Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 3828 The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 3829 - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 3830 Engine Control Module: Description and Operation Powertrain Control Module - Description Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors Modes Of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 3831 IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD or O2S heater relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 3832 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 3833 - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Ignition Circuit Sense IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). Power Grounds POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 3834 Sensor Return SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 3835 Engine Control Module: Description and Operation Powertrain Control Module - Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for a scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 3836 - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for diagnostic scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission convertor clutch circuit. Driven through J1850 circuits. 5 Volt Supplies 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel Engine Control Module: Testing and Inspection Engine Control Module (ECM) - Diesel ECM/PCM PROGRAMMING MODULE REPROGRAMING Replacement ECM's will require programming utilizing the StarSCAN(R) or equivalent. The ECM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic ECM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN and StarMOBILE or equivalent Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. NOTE: For the Cummins Diesel, if the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. 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. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3839 6. Replace the ECM with the appropriate Generic ECM. 7. Program the ECM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the ECM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "ECM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 10. 10. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a ECM and/or TCM. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3840 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. 5. Replace the ECM with the appropriate Generic ECM. . 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select "More Options". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3841 c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the ECM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "ECM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle is equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the ECM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3842 Engine Control Module: Testing and Inspection PCM/ECM Programming ECM/PCM PROGRAMMING MODULE REPROGRAMING Replacement ECM's will require programming utilizing the StarSCAN(R) or equivalent. The ECM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic ECM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN and StarMOBILE or equivalent Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. NOTE: For the Cummins Diesel, if the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. 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. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3843 6. Replace the ECM with the appropriate Generic ECM. 7. Program the ECM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the ECM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "ECM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 10. 10. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a ECM and/or TCM. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3844 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. 5. Replace the ECM with the appropriate Generic ECM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select "More Options". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3845 c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the ECM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "ECM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle is equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the ECM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3846 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED , ECM REPLACED , WCM REPLACED , or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3847 SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3848 Engine Control Module: Testing and Inspection Powertrain Control Module PCM/ECM REPROGRAMMING - GAS MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN(R) or equivalent and StarMOBILE Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is this a GPEC Module? a. Yes >> go to STEP 9. b. No >> go to STEP 12. 9. Do not start the engine prior to completing the following steps (a. and b.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3849 a. Turn the ignition switch to the OFF position for no less than 15 seconds. b. Turn the ignition to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. 10. Is this vehicle equipped with a CVT? a. Yes >> go to STEP 11. b. No >> go to STEP 17. 11. The TCM must be reprogrammed as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. NOTE: If the part number recorded in step "11e" is the same as the new p/n shown on the "Flash File List" screen no further action is required. Cancel the TCM reprogram procedure. Continue to step STEP 17. g. Highlight the appropriate calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". m. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. n. Continue to step STEP 15 12. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 13. b. No >> go to STEP 14. 13. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 15. 14. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 15. Is the vehicle equipped ETC? a. Yes >> go to STEP 17. b. No >> go to STEP 16. 16. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 17. Type the necessary information on the Authorized Modification Label p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3850 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R) or equivalent, refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under Training Aids and also under Download Center > Frequently Asked Questions for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 3851 d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel Engine Control Module: Service and Repair Engine Control Module (ECM) - Diesel 5.9L Diesel 5.9L DIESEL CUMMINS FUEL SYSTEM COMPONENTS The Engine Control Module (ECM) (16) is bolted to a support bracket near the fuel filter. The support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. 3. Remove the 50-way and 60-way connector bolts at the ECM. Note: The connector bolt is a female allen head. As bolt is being removed, very carefully remove connectors from the ECM. 4. Remove five ECM mounting bolts and remove ECM from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 3854 6.7L Diesel 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. 5.9L Diesel 5.9L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 3855 CUMMINS FUEL SYSTEM COMPONENTS Do not apply paint to ECM or a poor ground will result. 1. Position the ECM (16) to the ECM support bracket and install the five mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pin connectors in ECM, 50-way and 60-way connectors for corrosion or damage. Repair as necessary. 3. Clean pins in the 50-way and 60-way electrical connectors with a electrical contact cleaner. 4. Install the 50-way and 60-way connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Reconnect both negative battery cables. 6. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. 6.7L Diesel 6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 3856 Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM.FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 3857 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 3858 Engine Control Module: Service and Repair Powertrain Control Module - Removal REMOVAL CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (4) and remove PCM from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 3859 Engine Control Module: Service and Repair Powertrain Control Module - Installation INSTALLATION CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The scan tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3863 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3864 Main Relay (Computer/Fuel System): Diagrams Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3865 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3866 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3867 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3886 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3887 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3888 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3889 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3893 Fuel Pump Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3894 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 Intake Air Heater Relay: Locations Component ID 242 Component ID: 242 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 3899 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 3900 Intake Air Heater Relay: Locations Component ID 243 Component ID: 243 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 3901 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 Intake Air Heater Relay: Diagrams Component ID 242 Component ID: 242 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 3904 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 3905 Intake Air Heater Relay: Diagrams Component ID 243 Component ID: 243 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 3906 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Page 3907 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 3910 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3914 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3915 Main Relay (Computer/Fuel System): Diagrams Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3916 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3917 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3918 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3924 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3925 Accelerator Pedal Position Sensor: Diagrams Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3926 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 3929 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 3932 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3936 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3937 Air Flow Meter/Sensor: Diagrams Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3938 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3939 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 3942 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3946 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3947 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3948 Battery Temperature Sensor: Diagrams Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3949 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3950 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 3953 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20°F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 3956 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3960 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3961 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3962 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3963 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3964 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3965 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3966 Camshaft Position Sensor: Diagrams Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3967 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3968 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3969 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3970 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3971 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3972 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 3975 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor o-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3978 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor o-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3982 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3983 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3984 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3985 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3986 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3987 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3988 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3989 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3990 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3991 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3992 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3993 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3994 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3999 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) for the CKP is located behind the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 4002 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4006 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4007 Crankcase Pressure Sensor: Diagrams Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4008 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4013 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4014 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4015 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4016 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4017 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4018 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4019 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4020 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4023 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4024 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4025 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4026 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4027 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4028 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4029 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4030 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 4033 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 4036 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4041 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4042 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4043 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4044 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4045 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4046 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4049 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4050 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4051 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4052 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4053 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4054 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 4058 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 4059 High Idle Switch: Diagrams Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 4060 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4065 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4066 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4067 Intake Air Temperature Sensor: Connector Locations Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4068 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4069 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4070 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4071 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4072 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4073 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 421 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4076 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4077 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4078 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K21 20DB/LG IAT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4079 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4080 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4081 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4082 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4083 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4084 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4085 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4086 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4087 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4088 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4089 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4090 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4091 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 4092 Intake Air Temperature Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 4095 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 4100 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 4101 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 4102 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 4103 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 4104 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 4105 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 4106 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Map Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 4107 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 4108 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 4111 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 4112 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 4113 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 4114 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 4115 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 4116 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 4117 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Map Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 4118 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 4119 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Air Pressure (MAP) Sensor Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Air Pressure (MAP) Sensor DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Air Pressure (MAP) Sensor > Page 4122 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 4125 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 4126 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 4127 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4136 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4137 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4138 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4139 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4140 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4141 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4142 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4148 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4149 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4150 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4160 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4161 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4162 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4167 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4168 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4169 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4170 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4171 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4172 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4173 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4183 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4184 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 4185 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4195 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4196 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4197 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4198 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4199 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4200 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 4201 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 431 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4204 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4205 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4206 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4207 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4208 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4209 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4210 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4211 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 Z42 20BK/LG GROUND 3 K902 20BR/DG O2 RETURN (UPSTREAM) 4 K41 20DB/LB O2 1/1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4212 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4213 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4214 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4215 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4216 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 432 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4217 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4218 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4219 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4220 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4221 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4222 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 2 Z43 20BK/LB GROUND 3 K904 20DB/DG O2 RETURN (DOWNSTREAM) 4 K141 20DB/YL O2 1/2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4223 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4224 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 4225 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 209 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 3 D132 20WT DIAGNOSTIC PORT LOW DATA LINK 4 K141 20DB/YL O2 1/2 SIGNAL 5 K734 20BR/DG 02 1/2 PUMP CURRENT 6 K41 20DB/LB O2 1/1 SIGNAL 7 K89 20BR/LG 02 1/1 PUMP CURRENT 8 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 9 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 10 Z902 20BK GROUND 11 D133 20WT/OR DIAGNOSTIC PORT HIGH DATA LINK 12 K904 20DB/DG O2 1/2 RETURN 13 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 14 K902 20BR/DG O2 1/1 RETURN 15 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 16 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4228 Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 3 D132 20WT DIAGNOSTIC PORT LOW DATA LINK 4 K141 20DB/YL O2 1/2 SIGNAL 5 K734 20BR/DG 02 1/2 PUMP CURRENT 6 K41 20DB/LB O2 1/1 SIGNAL 7 K89 20BR/LG 02 1/1 PUMP CURRENT 8 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 9 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 10 Z902 20BK GROUND 11 D133 20WT/OR DIAGNOSTIC PORT HIGH DATA LINK 12 K904 20DB/DG O2 1/2 RETURN 13 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 14 K902 20BR/DG O2 1/1 RETURN 15 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 16 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4229 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 431 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4230 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4231 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4232 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4233 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4234 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4235 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4236 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4237 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 Z42 20BK/LG GROUND 3 K902 20BR/DG O2 RETURN (UPSTREAM) 4 K41 20DB/LB O2 1/1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4238 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4239 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4240 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4241 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4242 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 432 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4243 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4244 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4245 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4246 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4247 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4248 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 2 Z43 20BK/LB GROUND 3 K904 20DB/DG O2 RETURN (DOWNSTREAM) 4 K141 20DB/YL O2 1/2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4249 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4250 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 4251 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 4254 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 4255 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 4258 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 4259 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal.DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 4264 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4269 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4270 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4271 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4272 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4273 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4274 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4275 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4276 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4277 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4278 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 4279 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4282 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4283 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4284 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4285 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4286 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4287 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4288 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4289 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4290 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4291 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 4292 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4295 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4296 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 4297 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 4298 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4301 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4302 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4303 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 4304 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4309 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4310 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4311 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4312 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4313 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4314 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4315 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4316 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4317 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4318 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4319 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4320 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4321 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4322 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4323 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4324 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4330 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4331 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4332 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4333 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4334 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4335 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4336 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4337 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4340 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4341 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4342 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4343 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4344 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4345 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4346 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4347 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 4350 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 4353 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4357 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4358 Crankcase Pressure Sensor: Diagrams Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4359 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 409 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K935 18DB EGR TEMPERATURE SENSOR SIGNAL Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K935 18DB EGR TEMPERATURE SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 4365 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4368 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. 4. Unscrew nut (2) at intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4369 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4370 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4371 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 4372 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). PRESSURE DIFFERENTIAL TUBING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 4378 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 4379 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION PRESSURE DIFFERENTIAL TUBING 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 4380 NOTE: Make sure there is not a dip in the pressure differential hoses. 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 4385 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4390 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4391 Accelerator Pedal Position Sensor: Diagrams Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4392 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 4395 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 4398 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4402 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4403 Air Flow Meter/Sensor: Diagrams Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4404 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4405 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4408 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations Component ID: 419 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 K915 18BR/WT FUEL RAIL SENSOR RETURN Pin Circuit Description 1 K916 18BR/OR SENSOR GROUND 2 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 3 F855 18PK/YL 5 VOLT SUPPLY Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4412 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4413 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4414 Fuel Pressure Sensor/Switch: Diagrams Component ID: 419 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 K915 18BR/WT FUEL RAIL SENSOR RETURN Pin Circuit Description 1 K916 18BR/OR SENSOR GROUND 2 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 3 F855 18PK/YL 5 VOLT SUPPLY Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4415 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4416 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 4417 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 4420 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 4421 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components. 8. Start engine and check for fuel leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 4425 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 4426 High Idle Switch: Diagrams Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 4427 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Component ID: 446 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 2 K541 18BR/VT TURBO SPEED SENSOR GROUND Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 4431 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 4432 Turbo Boost Sensor: Diagrams Component ID: 446 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 2 K541 18BR/VT TURBO SPEED SENSOR GROUND Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 4433 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal Turbo Boost Sensor: Service and Repair Removal REMOVAL CAUTION: Do not use a screw driver or tool to pry sensor out of the turbocharger bearing housing. Damage to sensor may result. If sensor is damaged during removal, install a new sensor. 1. Disconnect negative battery cable. 2. Remove turbocharger oil supply line. 3. Disconnect speed sensor electrical connector. 4. Remove turbocharger speed sensor mounting bolt (1). 5. Remove turbocharger speed sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal > Page 4436 Turbo Boost Sensor: Service and Repair Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). 4. Connect speed sensor electrical connector. 5. Install turbocharger oil supply line. Tighten fitting to 24 Nm (18 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4441 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4442 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4443 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4444 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4445 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4446 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4447 Camshaft Position Sensor: Diagrams Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4448 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4449 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4450 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4451 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4452 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4453 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 4456 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor o-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 4459 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor o-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4464 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) for the CKP is located behind the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 4467 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 4473 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder. Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 4480 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than +/- 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 4481 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed Information Not Supplied by the Manufacturer Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL There is no longer a Filter Minder on the MY08 Diesel Engines. There will be an EVIC message which will display when the filter restriction reaches it's maximum. The customer will be required to replace it with-in 250 miles (402 KM) Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 4490 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 4495 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 4496 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Description and Operation > Description > Page 4499 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel Filter/Water Separator Removal/Installation. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules, for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4502 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4503 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4504 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. Refer to Standard Procedures-Fuel System Priming. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4505 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Removal > Page 4506 a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread O-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. The cylinders are numbered front to rear ; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Specifications Compression Ratio .............................................................................................................................. ....................................................................... 17.2 : 1 Compression Pressure (Minimum) ...................................................................................................... ....................................................................... 350 psi Max Variation Between Cylinders ........................................................................................................ ............................................................ Not available Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments VALVE LASH ADJUSTMENT AND VERIFICATION NOTE: To obtain accurate readings, valve lash measurements AND adjustments should only be performed when the engine coolant temperature is less than 60° C (140° F). The 24-valve overhead system is a "low-maintenance" design. Routine adjustments are no longer necessary, however, measurement should still take place when troubleshooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors. 1. Disconnect battery negative cables. 2. Remove cylinder head cover See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Removal . 3. Using the crankshaft barring tool #7471-B, rotate crankshaft to align damper TDC mark to 12:00 o'clock position. a. If both number one cylinder rocker levers are loose, continue to next step. b. If both number one cylinder rocker levers are not loose, rotate crankshaft 360 degrees. 4. With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1-2-4 / EXHAUST 1-3-5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead. Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjustment/resettingis not necessary. If measurement finds the lash outside of the limits, adjustment/resettingis required. 5. If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: - INTAKE 0.254 mm (0.010 in.) - EXHAUST 0.660 mm (0.026 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and recheck the valve lash. 6. Using the crankshaft barring tool, rotate the crankshaft one revolution (360°) to align the damper TDC mark to the 12 o'clock position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > Page 4516 7. With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3-5-6 / EXHAUST 2-4-6. Use the same method as above for determining whether adjustment is necessary, and adjust those that are found to be outside of the limits. 8. Install the cylinder head cover See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Installation . 9. Connect the battery negative cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4521 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4522 Accelerator Pedal Position Sensor: Diagrams Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4523 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 4526 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 4529 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4533 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4534 Air Flow Meter/Sensor: Diagrams Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4535 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4536 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 4539 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4544 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4545 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4546 Intake Air Temperature Sensor: Connector Locations Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4547 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4548 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4549 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4550 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4551 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4552 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 421 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4555 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4556 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4557 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K21 20DB/LG IAT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4558 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4559 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4560 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4561 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4562 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4563 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4564 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4565 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4566 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4567 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4568 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4569 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 4570 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 4571 Intake Air Temperature Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 4574 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4578 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4579 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4580 Battery Temperature Sensor: Diagrams Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4581 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 4582 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 4585 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20°F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 4588 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4593 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4594 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4595 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4596 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4597 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4598 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4599 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4600 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4601 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4602 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4603 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4604 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4605 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4606 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4607 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4608 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4612 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4613 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4614 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4615 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4616 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4617 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4618 Camshaft Position Sensor: Diagrams Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4619 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4620 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4621 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4622 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4623 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4624 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 4627 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor o-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 4630 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor o-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4635 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4636 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4637 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4638 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4639 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4640 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4641 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 4642 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4645 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4646 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4647 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4648 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4649 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4650 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4651 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 4652 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 4655 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 4658 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4662 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4663 Crankcase Pressure Sensor: Diagrams Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 4664 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4668 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4669 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4670 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4671 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4672 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4673 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4674 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4675 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4676 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4677 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4678 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4679 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 4680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4685 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) for the CKP is located behind the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 4688 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector Data Link Connector: Locations Data Link Connector Component ID: 82 Component : DATA LINK CONNECTOR Connector: Name : DATA LINK CONNECTOR Color : BLACK # of pins : 16 Pin Circuit Description 1-2-3-4 Z11 18BK/LG GROUND 5 Z111 18BK/WT GROUND 6 D52 20WT/LB DIAGNOSTIC CAN C (+) 7 D21 18WT/BR SCI TRANSMIT (ECM) 8-9-10 - 11 - 12 D20 20WT/LG SCI RECEIVE (ECM) 13 - 14 D51 20WT/BR DIAGNOSTIC CAN C (-) 15 - 16 A114 18GY/RD FUSED B(+) Component Location - 49 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector > Page 4693 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector > Page 4694 Data Link Connector: Locations Port-Diagnostic Component ID: 234 Component : PORT-DIAGNOSTIC Connector: Name : PORT-DIAGNOSTIC Color : # of pins : 3 Qualifier : (6.7L) A D132 18WT DIAGNOSTIC PORT LOW DATA LINK B D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK C-Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Data Link Connector > Page 4695 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4710 Data Link Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4711 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4712 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4713 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4714 Data Link Connector: Connector Views Data Link Connector Component ID: 82 Component : DATA LINK CONNECTOR Connector: Name : DATA LINK CONNECTOR Color : BLACK # of pins : 16 Pin Circuit Description 1-2-3-4 Z11 18BK/LG GROUND 5 Z111 18BK/WT GROUND 6 D52 20WT/LB DIAGNOSTIC CAN C (+) 7 D21 18WT/BR SCI TRANSMIT (ECM) 8-9-10 - 11 - 12 D20 20WT/LG SCI RECEIVE (ECM) 13 - 14 D51 20WT/BR DIAGNOSTIC CAN C (-) 15 - 16 A114 18GY/RD FUSED B(+) Component Location - 49 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 Port-Diagnostic Component ID: 234 Component : PORT-DIAGNOSTIC Connector: Name : PORT-DIAGNOSTIC Color : # of pins : 3 Qualifier : (6.7L) A D132 18WT DIAGNOSTIC PORT LOW DATA LINK B D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK C-Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Description Data Link Connector: Description and Operation Description DESCRIPTION The Data Link Connector (DLC) (3) is a 16-way molded plastic connector insulator on a dedicated take out of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in the lower instrument panel reinforcement (2), just below the lower edge of the instrument panel steering column opening cover (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Description > Page 4719 Data Link Connector: Description and Operation Operation OPERATION The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network of the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation > Description Electronic Throttle Control Indicator: Description and Operation Description DESCRIPTION An Electronic Throttle Control (ETC) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional 5.7 liter gasoline engine, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Electronic Throttle Control in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation > Description > Page 4724 Electronic Throttle Control Indicator: Description and Operation Operation OPERATION The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system, or a circuit or component of the system is ineffective. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ETC indicator is illuminated for about six seconds. The entire bulb test is a function of the PCM. - ETC Indicator Lamp-On Message - Each time the cluster receives an electronic ETC indicator lamp-ON message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about 12 seconds or until the cluster receives a lamp-OFF message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. The indicator will be extinguished when the ignition switch is turned to the OFF position. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-OFF message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the PCM sends a lamp-ON message after the bulb test, it indicates that the PCM has detected an ETC system malfunction or that the ETC system is ineffective. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, then the EMIC and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the EMIC, the CAN data bus or the electronic communication related to ETC indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4733 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4734 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4735 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4736 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4737 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4738 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4739 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 4745 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 4746 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 4747 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls CCN Update For Recall J35 > Page 4748 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4754 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4755 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4756 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4757 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4762 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4763 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4764 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4765 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4766 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4767 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4768 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4774 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4775 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4776 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 4777 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4783 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4784 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4785 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4786 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4787 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4788 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 4789 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 205 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Circuit Description 1 K139 18DB WASTEGATE SOLENOID CONTROL 2 G6 18VT/GY OIL PRESSURE SIGNAL 3-4 D65 18WT/LG CAN C BUS (+) 5 D64 18WT/LB CAN C BUS (-) 6 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 7 K20 18BR/GY GEN FIELD CONTROL 8 K314 18TN/YL TTVA MOTOR (+) 9-10 - 11 K923 18BR/WT WATER IN FUEL SENSOR GROUND 12 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 13 K615 18VT/WT INLET AIR TEMPERATURE SENSE 14 - 15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 K616 18BR/YL INLET AIR PRESSURE SENSE 17 K2 18VT/OR ECT SIGNAL 18 - 19 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER 20 K315 18TN/OR TTVA MOTOR (-) 21 K161 18BR/LB FAN SPEED SENSOR GROUND 22 K24 18BR/LB CKP SIGNAL 23 K200 18BR/YL SENSOR GROUND 24 K44 18DB/GY CMP SIGNAL 25 K668 18BR 5 VOLT SUPPLY 26 - 27 K853 18DB/BR 5 VOLT SUPPLY 28 - 29 K690 18BR/YL SENSOR GROUND 30 K11 16BR/YL INJECTOR CONTROL NO. 1 31 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 32 K944 18BK/GY CMP SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4792 33 K167 18BR/YL APPS NO. 1 RETURN 34 N210 18DB/DG FAN SPEED SENSOR SIGNAL 35 - 36 K14 16BR/TN INJECTOR CONTROL NO. 4 37 - 38 - 39 - 40 K13 16TN INJECTOR CONTROL NO. 3 41 K210 18DB/TN SENSOR GROUND 42 K852 18BR/VT 5 VOLT SUPPLY 43 K37 18LB BOOST PRESSURE SENSOR SIGNAL 44 - 45 - 46 K58 16BR/VT INJECTOR CONTROL NO. 6 47 - 48 - 49 - 50 K12 16BR/DB INJECTOR CONTROL NO. 2 51 - 52 K975 18BR/OR CKP SENSOR GROUND 53 K915 18BR/WT FUEL RAIL SENSOR RETURN 54 F855 18PK/YL 5 VOLT SUPPLY 55 - 56 K38 16GY INJECTOR CONTROL NO. 5 57 K229 16TN/PK INJECTOR HIGH SIDE DRIVER-BANK 2 58 - 59 K227 16BR/LG INJECTOR HIGH SIDE DRIVER-BANK 1 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4793 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4794 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4795 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K682 18DB/WT EGR CONTROL NO. 1 3 K684 18DB/YL EGR CONTROL NO. 2 4 K686 18GY/DB EGR CONTROL NO. 3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4796 5 K685 18DB EGR SIGNAL NO. 2 6-7 K161 18BR/LB FAN SPEED SENSOR GROUND 8-9 K670 18BR/LB EGR BYPASS VALVE SIGNAL 10 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN 11 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 12 - 13 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 14 K926 18DB/GY CRANKCASE SENSOR SIGNAL 15 K2 18VT/OR ECT SIGNAL 16 - 17 K671 18BR/DB EGR BYPASS STATUS 18 N27 18DB/GY FAN SPEED SENSOR SIGNAL 19 K37 18BR BOOST PRESSURE SENSOR SIGNAL 20 K616 18BR/YL INLET AIR PRESSURE SENSE 21 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 22 K971 18BR/PK SENSOR GROUND 23 - 24 K615 18VT/WT INLET AIR TEMPERATURE SENSE 25 K683 18DB/GY EGR SIGNAL NO. 1 26 K824 18DB/BR 5 VOLT SUPPLY 27 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 28 A804 18RD GEN SENSE 29 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 30 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 31 K24 18BR/LB CKP SIGNAL 32 G6 18VT/GY OIL PRESSURE SIGNAL 33 K972 18DB/TN ACTUATOR GROUND 34 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 35 K687 18DB/LB EGR SIGNAL NO. 3 36 F855 18PK/YL 5 VOLT SUPPLY 37 K44 18DB/GY CMP SIGNAL 38 D130 18BR/VT ACTUATOR HIGH DATA LINK 39 D131 18WT/LG ACTUATOR LOW DATA LINK 40 K20 18BR/GY GEN FIELD CONTROL 41 K935 18DB EGR TEMPERATURE SENSOR SIGNAL 42 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 43 K541 18BR/VT TURBO SPEED SENSOR GROUND 44 K925 18BR/OR CKP SENSOR GROUND 45 K58 16BR/VT INJECTOR CONTROL NO. 6 46 K12 16BR/DB INJECTOR CONTROL NO. 2 47 K914 18BR/WT SENSOR GROUND 48 K916 18BR/OR SENSOR GROUND 49 - 50 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL 51 K613 16GY/BR INJECTOR HIGH SIDE DRIVER NO. 3 52 K612 16YL/BR INJECTOR HIGH SIDE DRIVER NO. 2 53 K611 16OR/BR INJECTOR HIGH SIDE DRIVER NO. 1 54 K14 16BR/TN INJECTOR CONTROL NO. 4 55 K38 16GY INJECTOR CONTROL NO. 5 56 K13 16TN INJECTOR CONTROL NO. 3 57 K11 16BR/YL INJECTOR CONTROL NO. 1 58 K658 16LG/BR INJECTOR HIGH SIDE DRIVER NO. 6 59 K638 16LB/BR INJECTOR HIGH SIDE DRIVER NO. 5 60 K614 16WT/BR INJECTOR HIGH SIDE DRIVER NO. 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4797 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4798 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4799 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Circuit Description 1-2-3 K23 18BR/WT APPS NO. 1 SIGNAL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4800 5 T515 18YL/DB TRANSMISSION CONTROL 6 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 7 K31 18BR FUEL PUMP CONTROL 8-9 T41 18YL/DB TRS T41 SIGNAL (P/N) 10 - 11 - 12 - 13 T6 18DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 14 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 15 T9 18DG/TN 3-4 SOLENOID CONTROL 16 - 17 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 18 - 19 - 20 A209 16RD FUSED B(+) 21 Z902 16BK GROUND 22 - 23 F856 18YL/PK 5 VOLT SUPPLY 24 K900 18DB/DG SENSOR GROUND 25 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 26 - 27 K312 18OR TTVA POSITION SENSOR SIGNAL 28 - 29 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL 30 A209 16RD FUSED B(+) 31 - 32 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 K854 18VT/BR 5 VOLT SUPPLY 34 - 35 K29 18WT/BR APPS NO. 2 SIGNAL 36 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 37 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 38 - 39 - 40 A209 16RD FUSED B(+) 41 C13 18LB/OR A/C CLUTCH CONTROL 42 - 43 K160 18BR/OR PWM FAN COIL SIGNAL 44 T14 18DG/BR OUTPUT SPEED SIGNAL 45 T13 18DG/VT SPEED SENSOR GROUND 46 V37 18VT S/C SWITCH NO. 1 SIGNAL 47 K25 18DB/VT BATT TEMP SIGNAL 48 K400 18BR/VT APPS NO. 2 RETURN 49 Z902 16BK GROUND 50 Z902 16BK GROUND Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4801 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4802 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4803 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 D65 18WT/LG CAN C BUS (+) 2 K31 18BR FUEL PUMP CONTROL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4804 5 G905 18BR/OR EXHAUST BRAKE SWITCH SIGNAL 6 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 7 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 8 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 9 K186 18BR/OR EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 10 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 11 - 12 - 13 - 14 - 15 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 16 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 17 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 18 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 19 - 20 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 21 D64 18WT/LB CAN C BUS (-) 22 K400 18BR/VT APPS NO. 2 RETURN 23 - 24 K29 18WT/BR APPS NO. 2 SIGNAL 25 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 26 K854 18VT/BR 5 VOLT SUPPLY 27 K852 18BR/LB 5 VOLT SUPPLY 28 K167 18BR/DG APPS NO. 1 RETURN 29 K900 18DB/DG SENSOR GROUND 30 K25 18DB/VT BATT TEMP SIGNAL 31 D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK 32 - 33 V937 18VT/BR S/C SWITCH RETURN 34 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 35 K23 18BR/WT APPS NO. 1 SIGNAL 36 - 37 K128 18DG/LG REMOTE THROTTLE SIGNAL 38 - 39 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 40 V37 18VT S/C SWITCH NO. 1 SIGNAL 41 - 42 - 43 K348 18BR SMART POWER RELAY RETURN 44 C13 18LB A/C CLUTCH CONTROL 45 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 46 - 47 Z902 16BK GROUND 48 Z902 16BK GROUND 49 A209 16RD FUSED B(+) 50 A209 16RD FUSED B(+) 51 D132 18WT DIAGNOSTIC PORT LOW DATA LINK 52 - 53 - 54 G904 18VT/DG EXHAUST BRAKE LAMP SIGNAL 55 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 56 V38 18VT/OR S/C SWITCH NO. 2 SIGNAL 57 Z902 16BK GROUND 58 - 59 - 60 A209 16RD FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4805 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4806 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4808 Engine Control Module: Locations Module-Powertrain Control Component ID 198 Component ID: 198 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 12345- 6789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4809 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4810 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4811 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4812 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4813 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4814 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4815 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4816 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4817 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4818 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4819 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4820 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4821 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4822 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4823 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4824 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4825 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4826 Component ID 211 Component ID: 211 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4827 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4828 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4829 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4830 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4831 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4832 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4833 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4834 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4835 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4836 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4837 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4838 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4839 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4840 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4841 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4842 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4843 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 4844 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4853 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4854 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4857 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4858 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4859 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4860 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4861 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4862 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4863 Engine Control Module: Connector Views Module-Engine Control Component ID: 205 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Circuit Description 1 K139 18DB WASTEGATE SOLENOID CONTROL 2 G6 18VT/GY OIL PRESSURE SIGNAL 3-4 D65 18WT/LG CAN C BUS (+) 5 D64 18WT/LB CAN C BUS (-) 6 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 7 K20 18BR/GY GEN FIELD CONTROL 8 K314 18TN/YL TTVA MOTOR (+) 9-10 - 11 K923 18BR/WT WATER IN FUEL SENSOR GROUND 12 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 13 K615 18VT/WT INLET AIR TEMPERATURE SENSE 14 - 15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 K616 18BR/YL INLET AIR PRESSURE SENSE 17 K2 18VT/OR ECT SIGNAL 18 - 19 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER 20 K315 18TN/OR TTVA MOTOR (-) 21 K161 18BR/LB FAN SPEED SENSOR GROUND 22 K24 18BR/LB CKP SIGNAL 23 K200 18BR/YL SENSOR GROUND 24 K44 18DB/GY CMP SIGNAL 25 K668 18BR 5 VOLT SUPPLY 26 - 27 K853 18DB/BR 5 VOLT SUPPLY 28 - 29 K690 18BR/YL SENSOR GROUND 30 K11 16BR/YL INJECTOR CONTROL NO. 1 31 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 32 K944 18BK/GY CMP SENSOR GROUND 33 K167 18BR/YL APPS NO. 1 RETURN 34 N210 18DB/DG FAN SPEED SENSOR SIGNAL 35 - 36 K14 16BR/TN INJECTOR CONTROL NO. 4 37 - 38 - 39 - 40 K13 16TN INJECTOR CONTROL NO. 3 41 K210 18DB/TN SENSOR GROUND 42 K852 18BR/VT 5 VOLT SUPPLY 43 K37 18LB BOOST PRESSURE SENSOR SIGNAL 44 - 45 - 46 K58 16BR/VT INJECTOR CONTROL NO. 6 47 - 48 - 49 - 50 K12 16BR/DB INJECTOR CONTROL NO. 2 51 - 52 K975 18BR/OR CKP SENSOR GROUND 53 K915 18BR/WT FUEL RAIL SENSOR RETURN 54 F855 18PK/YL 5 VOLT SUPPLY 55 - 56 K38 16GY INJECTOR CONTROL NO. 5 57 K229 16TN/PK INJECTOR HIGH SIDE DRIVER-BANK 2 58 - 59 K227 16BR/LG INJECTOR HIGH SIDE DRIVER-BANK 1 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K682 18DB/WT EGR CONTROL NO. 1 3 K684 18DB/YL EGR CONTROL NO. 2 4 K686 18GY/DB EGR CONTROL NO. 3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 5 K685 18DB EGR SIGNAL NO. 2 6-7 K161 18BR/LB FAN SPEED SENSOR GROUND 8-9 K670 18BR/LB EGR BYPASS VALVE SIGNAL 10 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN 11 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 12 - 13 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 14 K926 18DB/GY CRANKCASE SENSOR SIGNAL 15 K2 18VT/OR ECT SIGNAL 16 - 17 K671 18BR/DB EGR BYPASS STATUS 18 N27 18DB/GY FAN SPEED SENSOR SIGNAL 19 K37 18BR BOOST PRESSURE SENSOR SIGNAL 20 K616 18BR/YL INLET AIR PRESSURE SENSE 21 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 22 K971 18BR/PK SENSOR GROUND 23 - 24 K615 18VT/WT INLET AIR TEMPERATURE SENSE 25 K683 18DB/GY EGR SIGNAL NO. 1 26 K824 18DB/BR 5 VOLT SUPPLY 27 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 28 A804 18RD GEN SENSE 29 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 30 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 31 K24 18BR/LB CKP SIGNAL 32 G6 18VT/GY OIL PRESSURE SIGNAL 33 K972 18DB/TN ACTUATOR GROUND 34 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 35 K687 18DB/LB EGR SIGNAL NO. 3 36 F855 18PK/YL 5 VOLT SUPPLY 37 K44 18DB/GY CMP SIGNAL 38 D130 18BR/VT ACTUATOR HIGH DATA LINK 39 D131 18WT/LG ACTUATOR LOW DATA LINK 40 K20 18BR/GY GEN FIELD CONTROL 41 K935 18DB EGR TEMPERATURE SENSOR SIGNAL 42 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 43 K541 18BR/VT TURBO SPEED SENSOR GROUND 44 K925 18BR/OR CKP SENSOR GROUND 45 K58 16BR/VT INJECTOR CONTROL NO. 6 46 K12 16BR/DB INJECTOR CONTROL NO. 2 47 K914 18BR/WT SENSOR GROUND 48 K916 18BR/OR SENSOR GROUND 49 - 50 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL 51 K613 16GY/BR INJECTOR HIGH SIDE DRIVER NO. 3 52 K612 16YL/BR INJECTOR HIGH SIDE DRIVER NO. 2 53 K611 16OR/BR INJECTOR HIGH SIDE DRIVER NO. 1 54 K14 16BR/TN INJECTOR CONTROL NO. 4 55 K38 16GY INJECTOR CONTROL NO. 5 56 K13 16TN INJECTOR CONTROL NO. 3 57 K11 16BR/YL INJECTOR CONTROL NO. 1 58 K658 16LG/BR INJECTOR HIGH SIDE DRIVER NO. 6 59 K638 16LB/BR INJECTOR HIGH SIDE DRIVER NO. 5 60 K614 16WT/BR INJECTOR HIGH SIDE DRIVER NO. 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Circuit Description 1-2-3 K23 18BR/WT APPS NO. 1 SIGNAL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 5 T515 18YL/DB TRANSMISSION CONTROL 6 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 7 K31 18BR FUEL PUMP CONTROL 8-9 T41 18YL/DB TRS T41 SIGNAL (P/N) 10 - 11 - 12 - 13 T6 18DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 14 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 15 T9 18DG/TN 3-4 SOLENOID CONTROL 16 - 17 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 18 - 19 - 20 A209 16RD FUSED B(+) 21 Z902 16BK GROUND 22 - 23 F856 18YL/PK 5 VOLT SUPPLY 24 K900 18DB/DG SENSOR GROUND 25 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 26 - 27 K312 18OR TTVA POSITION SENSOR SIGNAL 28 - 29 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL 30 A209 16RD FUSED B(+) 31 - 32 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 K854 18VT/BR 5 VOLT SUPPLY 34 - 35 K29 18WT/BR APPS NO. 2 SIGNAL 36 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 37 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 38 - 39 - 40 A209 16RD FUSED B(+) 41 C13 18LB/OR A/C CLUTCH CONTROL 42 - 43 K160 18BR/OR PWM FAN COIL SIGNAL 44 T14 18DG/BR OUTPUT SPEED SIGNAL 45 T13 18DG/VT SPEED SENSOR GROUND 46 V37 18VT S/C SWITCH NO. 1 SIGNAL 47 K25 18DB/VT BATT TEMP SIGNAL 48 K400 18BR/VT APPS NO. 2 RETURN 49 Z902 16BK GROUND 50 Z902 16BK GROUND Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 D65 18WT/LG CAN C BUS (+) 2 K31 18BR FUEL PUMP CONTROL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 5 G905 18BR/OR EXHAUST BRAKE SWITCH SIGNAL 6 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 7 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 8 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 9 K186 18BR/OR EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 10 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 11 - 12 - 13 - 14 - 15 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 16 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 17 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 18 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 19 - 20 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 21 D64 18WT/LB CAN C BUS (-) 22 K400 18BR/VT APPS NO. 2 RETURN 23 - 24 K29 18WT/BR APPS NO. 2 SIGNAL 25 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 26 K854 18VT/BR 5 VOLT SUPPLY 27 K852 18BR/LB 5 VOLT SUPPLY 28 K167 18BR/DG APPS NO. 1 RETURN 29 K900 18DB/DG SENSOR GROUND 30 K25 18DB/VT BATT TEMP SIGNAL 31 D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK 32 - 33 V937 18VT/BR S/C SWITCH RETURN 34 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 35 K23 18BR/WT APPS NO. 1 SIGNAL 36 - 37 K128 18DG/LG REMOTE THROTTLE SIGNAL 38 - 39 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 40 V37 18VT S/C SWITCH NO. 1 SIGNAL 41 - 42 - 43 K348 18BR SMART POWER RELAY RETURN 44 C13 18LB A/C CLUTCH CONTROL 45 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 46 - 47 Z902 16BK GROUND 48 Z902 16BK GROUND 49 A209 16RD FUSED B(+) 50 A209 16RD FUSED B(+) 51 D132 18WT DIAGNOSTIC PORT LOW DATA LINK 52 - 53 - 54 G904 18VT/DG EXHAUST BRAKE LAMP SIGNAL 55 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 56 V38 18VT/OR S/C SWITCH NO. 2 SIGNAL 57 Z902 16BK GROUND 58 - 59 - 60 A209 16RD FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 Component ID 198 Component ID: 198 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4881 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 Component ID 211 Component ID: 211 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4906 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4907 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4908 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel Engine Control Module: Description and Operation Engine Control Module (ECM) - Diesel Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 4918 The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 4919 - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 4920 Engine Control Module: Description and Operation Powertrain Control Module - Description Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors Modes Of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 4921 IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD or O2S heater relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 4922 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 4923 - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Ignition Circuit Sense IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). Power Grounds POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 4924 Sensor Return SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 4925 Engine Control Module: Description and Operation Powertrain Control Module - Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for a scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 4926 - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for diagnostic scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission convertor clutch circuit. Driven through J1850 circuits. 5 Volt Supplies 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel Engine Control Module: Testing and Inspection Engine Control Module (ECM) - Diesel ECM/PCM PROGRAMMING MODULE REPROGRAMING Replacement ECM's will require programming utilizing the StarSCAN(R) or equivalent. The ECM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic ECM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN and StarMOBILE or equivalent Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. NOTE: For the Cummins Diesel, if the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. 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. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4929 6. Replace the ECM with the appropriate Generic ECM. 7. Program the ECM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the ECM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "ECM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 10. 10. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a ECM and/or TCM. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4930 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. 5. Replace the ECM with the appropriate Generic ECM. . 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select "More Options". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4931 c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the ECM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "ECM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle is equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the ECM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4932 Engine Control Module: Testing and Inspection PCM/ECM Programming ECM/PCM PROGRAMMING MODULE REPROGRAMING Replacement ECM's will require programming utilizing the StarSCAN(R) or equivalent. The ECM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic ECM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN and StarMOBILE or equivalent Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. NOTE: For the Cummins Diesel, if the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. 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. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4933 6. Replace the ECM with the appropriate Generic ECM. 7. Program the ECM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the ECM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "ECM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 10. 10. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a ECM and/or TCM. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4934 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. 5. Replace the ECM with the appropriate Generic ECM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select "More Options". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4935 c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the ECM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "ECM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle is equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the ECM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4936 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED , ECM REPLACED , WCM REPLACED , or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4937 SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4938 Engine Control Module: Testing and Inspection Powertrain Control Module PCM/ECM REPROGRAMMING - GAS MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN(R) or equivalent and StarMOBILE Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is this a GPEC Module? a. Yes >> go to STEP 9. b. No >> go to STEP 12. 9. Do not start the engine prior to completing the following steps (a. and b.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4939 a. Turn the ignition switch to the OFF position for no less than 15 seconds. b. Turn the ignition to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. 10. Is this vehicle equipped with a CVT? a. Yes >> go to STEP 11. b. No >> go to STEP 17. 11. The TCM must be reprogrammed as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. NOTE: If the part number recorded in step "11e" is the same as the new p/n shown on the "Flash File List" screen no further action is required. Cancel the TCM reprogram procedure. Continue to step STEP 17. g. Highlight the appropriate calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". m. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. n. Continue to step STEP 15 12. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 13. b. No >> go to STEP 14. 13. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 15. 14. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 15. Is the vehicle equipped ETC? a. Yes >> go to STEP 17. b. No >> go to STEP 16. 16. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 17. Type the necessary information on the Authorized Modification Label p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4940 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R) or equivalent, refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under Training Aids and also under Download Center > Frequently Asked Questions for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 4941 d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel Engine Control Module: Service and Repair Engine Control Module (ECM) - Diesel 5.9L Diesel 5.9L DIESEL CUMMINS FUEL SYSTEM COMPONENTS The Engine Control Module (ECM) (16) is bolted to a support bracket near the fuel filter. The support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. 3. Remove the 50-way and 60-way connector bolts at the ECM. Note: The connector bolt is a female allen head. As bolt is being removed, very carefully remove connectors from the ECM. 4. Remove five ECM mounting bolts and remove ECM from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 4944 6.7L Diesel 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. 5.9L Diesel 5.9L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 4945 CUMMINS FUEL SYSTEM COMPONENTS Do not apply paint to ECM or a poor ground will result. 1. Position the ECM (16) to the ECM support bracket and install the five mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pin connectors in ECM, 50-way and 60-way connectors for corrosion or damage. Repair as necessary. 3. Clean pins in the 50-way and 60-way electrical connectors with a electrical contact cleaner. 4. Install the 50-way and 60-way connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Reconnect both negative battery cables. 6. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. 6.7L Diesel 6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 4946 Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM.FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 4947 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 4948 Engine Control Module: Service and Repair Powertrain Control Module - Removal REMOVAL CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (4) and remove PCM from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 4949 Engine Control Module: Service and Repair Powertrain Control Module - Installation INSTALLATION CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The scan tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4954 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4955 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4956 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4957 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4958 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 4959 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4962 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4963 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4964 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4965 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4966 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 4967 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 4971 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 4972 High Idle Switch: Diagrams Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 4973 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4979 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4980 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4981 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4982 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4983 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4984 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4985 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4986 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4987 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4988 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4989 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4990 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4991 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4992 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4993 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4994 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-18-02 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4995 8w-18-03 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 8w-18-04 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 8w-18-05 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4998 8w-18-06 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5002 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5003 Main Relay (Computer/Fuel System): Diagrams Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5004 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5005 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5006 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Description Malfunction Indicator Lamp: Description and Operation Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Description > Page 5011 Malfunction Indicator Lamp: Description and Operation Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-ON message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated solid, as dictated by the PCM or ECM message. For some DTCs, if a problem does not recur, the PCM or ECM will send a lamp-OFF message automatically. Other DTCs may require that a fault be repaired and the PCM or ECM be reset before a lamp-OFF message will be sent. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM or ECM for about 10 seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the EMIC turns ON the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the EMIC, the CAN data bus or the electronic communication related to MIL operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5016 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5017 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5018 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5019 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5020 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5021 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5022 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Map Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5023 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5024 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5027 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5028 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5029 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5030 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5031 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5032 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5033 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Map Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5034 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5035 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Air Pressure (MAP) Sensor Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Air Pressure (MAP) Sensor DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Air Pressure (MAP) Sensor > Page 5038 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5041 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5042 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5043 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5052 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5053 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5054 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5055 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5056 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5057 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5058 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5064 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5065 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5066 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5076 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5077 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5078 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5083 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5084 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5085 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5086 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5087 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5088 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall O2 Sensor Replacement/ECM Software Update > Page 5089 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5099 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5100 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5101 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5111 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5112 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5113 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5114 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5115 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5116 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5117 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 431 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5120 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5121 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5122 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5123 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5124 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5125 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5126 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5127 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 Z42 20BK/LG GROUND 3 K902 20BR/DG O2 RETURN (UPSTREAM) 4 K41 20DB/LB O2 1/1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5128 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5129 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5130 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5131 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5132 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 432 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5133 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5134 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5135 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5136 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5137 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5138 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 2 Z43 20BK/LB GROUND 3 K904 20DB/DG O2 RETURN (DOWNSTREAM) 4 K141 20DB/YL O2 1/2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5139 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5140 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5141 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 209 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 3 D132 20WT DIAGNOSTIC PORT LOW DATA LINK 4 K141 20DB/YL O2 1/2 SIGNAL 5 K734 20BR/DG 02 1/2 PUMP CURRENT 6 K41 20DB/LB O2 1/1 SIGNAL 7 K89 20BR/LG 02 1/1 PUMP CURRENT 8 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 9 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 10 Z902 20BK GROUND 11 D133 20WT/OR DIAGNOSTIC PORT HIGH DATA LINK 12 K904 20DB/DG O2 1/2 RETURN 13 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 14 K902 20BR/DG O2 1/1 RETURN 15 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 16 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5144 Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 3 D132 20WT DIAGNOSTIC PORT LOW DATA LINK 4 K141 20DB/YL O2 1/2 SIGNAL 5 K734 20BR/DG 02 1/2 PUMP CURRENT 6 K41 20DB/LB O2 1/1 SIGNAL 7 K89 20BR/LG 02 1/1 PUMP CURRENT 8 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 9 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 10 Z902 20BK GROUND 11 D133 20WT/OR DIAGNOSTIC PORT HIGH DATA LINK 12 K904 20DB/DG O2 1/2 RETURN 13 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 14 K902 20BR/DG O2 1/1 RETURN 15 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 16 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5145 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 431 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5146 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5147 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5148 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5149 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5150 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5151 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5152 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5153 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 Z42 20BK/LG GROUND 3 K902 20BR/DG O2 RETURN (UPSTREAM) 4 K41 20DB/LB O2 1/1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5154 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5155 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5156 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5157 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5158 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 432 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5159 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5160 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5161 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5162 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5163 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5164 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 2 Z43 20BK/LB GROUND 3 K904 20DB/DG O2 RETURN (DOWNSTREAM) 4 K141 20DB/YL O2 1/2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5165 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5166 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5167 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 5170 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description - Pick Up Models > Page 5171 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5174 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5175 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal.DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 5183 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5213 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5214 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5215 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5216 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5217 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5218 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5219 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5225 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5226 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5227 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5228 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5234 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5235 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5236 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5237 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5242 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5243 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5244 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5245 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5246 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5247 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5248 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 Engine Control Module: All Technical Service Bulletins Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5254 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5255 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5256 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 5257 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5263 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5264 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5265 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5266 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5267 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5268 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 5269 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control Engine Control Module: Locations Module-Engine Control Component ID: 205 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Circuit Description 1 K139 18DB WASTEGATE SOLENOID CONTROL 2 G6 18VT/GY OIL PRESSURE SIGNAL 3-4 D65 18WT/LG CAN C BUS (+) 5 D64 18WT/LB CAN C BUS (-) 6 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 7 K20 18BR/GY GEN FIELD CONTROL 8 K314 18TN/YL TTVA MOTOR (+) 9-10 - 11 K923 18BR/WT WATER IN FUEL SENSOR GROUND 12 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 13 K615 18VT/WT INLET AIR TEMPERATURE SENSE 14 - 15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 K616 18BR/YL INLET AIR PRESSURE SENSE 17 K2 18VT/OR ECT SIGNAL 18 - 19 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER 20 K315 18TN/OR TTVA MOTOR (-) 21 K161 18BR/LB FAN SPEED SENSOR GROUND 22 K24 18BR/LB CKP SIGNAL 23 K200 18BR/YL SENSOR GROUND 24 K44 18DB/GY CMP SIGNAL 25 K668 18BR 5 VOLT SUPPLY 26 - 27 K853 18DB/BR 5 VOLT SUPPLY 28 - 29 K690 18BR/YL SENSOR GROUND 30 K11 16BR/YL INJECTOR CONTROL NO. 1 31 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 32 K944 18BK/GY CMP SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5272 33 K167 18BR/YL APPS NO. 1 RETURN 34 N210 18DB/DG FAN SPEED SENSOR SIGNAL 35 - 36 K14 16BR/TN INJECTOR CONTROL NO. 4 37 - 38 - 39 - 40 K13 16TN INJECTOR CONTROL NO. 3 41 K210 18DB/TN SENSOR GROUND 42 K852 18BR/VT 5 VOLT SUPPLY 43 K37 18LB BOOST PRESSURE SENSOR SIGNAL 44 - 45 - 46 K58 16BR/VT INJECTOR CONTROL NO. 6 47 - 48 - 49 - 50 K12 16BR/DB INJECTOR CONTROL NO. 2 51 - 52 K975 18BR/OR CKP SENSOR GROUND 53 K915 18BR/WT FUEL RAIL SENSOR RETURN 54 F855 18PK/YL 5 VOLT SUPPLY 55 - 56 K38 16GY INJECTOR CONTROL NO. 5 57 K229 16TN/PK INJECTOR HIGH SIDE DRIVER-BANK 2 58 - 59 K227 16BR/LG INJECTOR HIGH SIDE DRIVER-BANK 1 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5273 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5274 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5275 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K682 18DB/WT EGR CONTROL NO. 1 3 K684 18DB/YL EGR CONTROL NO. 2 4 K686 18GY/DB EGR CONTROL NO. 3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5276 5 K685 18DB EGR SIGNAL NO. 2 6-7 K161 18BR/LB FAN SPEED SENSOR GROUND 8-9 K670 18BR/LB EGR BYPASS VALVE SIGNAL 10 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN 11 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 12 - 13 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 14 K926 18DB/GY CRANKCASE SENSOR SIGNAL 15 K2 18VT/OR ECT SIGNAL 16 - 17 K671 18BR/DB EGR BYPASS STATUS 18 N27 18DB/GY FAN SPEED SENSOR SIGNAL 19 K37 18BR BOOST PRESSURE SENSOR SIGNAL 20 K616 18BR/YL INLET AIR PRESSURE SENSE 21 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 22 K971 18BR/PK SENSOR GROUND 23 - 24 K615 18VT/WT INLET AIR TEMPERATURE SENSE 25 K683 18DB/GY EGR SIGNAL NO. 1 26 K824 18DB/BR 5 VOLT SUPPLY 27 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 28 A804 18RD GEN SENSE 29 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 30 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 31 K24 18BR/LB CKP SIGNAL 32 G6 18VT/GY OIL PRESSURE SIGNAL 33 K972 18DB/TN ACTUATOR GROUND 34 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 35 K687 18DB/LB EGR SIGNAL NO. 3 36 F855 18PK/YL 5 VOLT SUPPLY 37 K44 18DB/GY CMP SIGNAL 38 D130 18BR/VT ACTUATOR HIGH DATA LINK 39 D131 18WT/LG ACTUATOR LOW DATA LINK 40 K20 18BR/GY GEN FIELD CONTROL 41 K935 18DB EGR TEMPERATURE SENSOR SIGNAL 42 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 43 K541 18BR/VT TURBO SPEED SENSOR GROUND 44 K925 18BR/OR CKP SENSOR GROUND 45 K58 16BR/VT INJECTOR CONTROL NO. 6 46 K12 16BR/DB INJECTOR CONTROL NO. 2 47 K914 18BR/WT SENSOR GROUND 48 K916 18BR/OR SENSOR GROUND 49 - 50 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL 51 K613 16GY/BR INJECTOR HIGH SIDE DRIVER NO. 3 52 K612 16YL/BR INJECTOR HIGH SIDE DRIVER NO. 2 53 K611 16OR/BR INJECTOR HIGH SIDE DRIVER NO. 1 54 K14 16BR/TN INJECTOR CONTROL NO. 4 55 K38 16GY INJECTOR CONTROL NO. 5 56 K13 16TN INJECTOR CONTROL NO. 3 57 K11 16BR/YL INJECTOR CONTROL NO. 1 58 K658 16LG/BR INJECTOR HIGH SIDE DRIVER NO. 6 59 K638 16LB/BR INJECTOR HIGH SIDE DRIVER NO. 5 60 K614 16WT/BR INJECTOR HIGH SIDE DRIVER NO. 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5277 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5278 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5279 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Circuit Description 1-2-3 K23 18BR/WT APPS NO. 1 SIGNAL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5280 5 T515 18YL/DB TRANSMISSION CONTROL 6 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 7 K31 18BR FUEL PUMP CONTROL 8-9 T41 18YL/DB TRS T41 SIGNAL (P/N) 10 - 11 - 12 - 13 T6 18DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 14 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 15 T9 18DG/TN 3-4 SOLENOID CONTROL 16 - 17 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 18 - 19 - 20 A209 16RD FUSED B(+) 21 Z902 16BK GROUND 22 - 23 F856 18YL/PK 5 VOLT SUPPLY 24 K900 18DB/DG SENSOR GROUND 25 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 26 - 27 K312 18OR TTVA POSITION SENSOR SIGNAL 28 - 29 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL 30 A209 16RD FUSED B(+) 31 - 32 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 K854 18VT/BR 5 VOLT SUPPLY 34 - 35 K29 18WT/BR APPS NO. 2 SIGNAL 36 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 37 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 38 - 39 - 40 A209 16RD FUSED B(+) 41 C13 18LB/OR A/C CLUTCH CONTROL 42 - 43 K160 18BR/OR PWM FAN COIL SIGNAL 44 T14 18DG/BR OUTPUT SPEED SIGNAL 45 T13 18DG/VT SPEED SENSOR GROUND 46 V37 18VT S/C SWITCH NO. 1 SIGNAL 47 K25 18DB/VT BATT TEMP SIGNAL 48 K400 18BR/VT APPS NO. 2 RETURN 49 Z902 16BK GROUND 50 Z902 16BK GROUND Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5281 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5282 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5283 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 D65 18WT/LG CAN C BUS (+) 2 K31 18BR FUEL PUMP CONTROL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5284 5 G905 18BR/OR EXHAUST BRAKE SWITCH SIGNAL 6 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 7 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 8 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 9 K186 18BR/OR EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 10 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 11 - 12 - 13 - 14 - 15 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 16 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 17 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 18 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 19 - 20 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 21 D64 18WT/LB CAN C BUS (-) 22 K400 18BR/VT APPS NO. 2 RETURN 23 - 24 K29 18WT/BR APPS NO. 2 SIGNAL 25 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 26 K854 18VT/BR 5 VOLT SUPPLY 27 K852 18BR/LB 5 VOLT SUPPLY 28 K167 18BR/DG APPS NO. 1 RETURN 29 K900 18DB/DG SENSOR GROUND 30 K25 18DB/VT BATT TEMP SIGNAL 31 D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK 32 - 33 V937 18VT/BR S/C SWITCH RETURN 34 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 35 K23 18BR/WT APPS NO. 1 SIGNAL 36 - - 37 K128 18DG/LG REMOTE THROTTLE SIGNAL 38 - 39 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 40 V37 18VT S/C SWITCH NO. 1 SIGNAL 41 - 42 - 43 K348 18BR SMART POWER RELAY RETURN 44 C13 18LB A/C CLUTCH CONTROL 45 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 46 - 47 Z902 16BK GROUND 48 Z902 16BK GROUND 49 A209 16RD FUSED B(+) 50 A209 16RD FUSED B(+) 51 D132 18WT DIAGNOSTIC PORT LOW DATA LINK 52 - 53 - 54 G904 18VT/DG EXHAUST BRAKE LAMP SIGNAL 55 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 56 V38 18VT/OR S/C SWITCH NO. 2 SIGNAL 57 Z902 16BK GROUND 58 - 59 - 60 A209 16RD FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5285 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5286 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5287 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5288 Engine Control Module: Locations Module-Powertrain Control Component ID 198 Component ID: 198 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 12345- 6789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5289 18 - - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5290 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5291 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5292 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5293 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5294 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5295 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5296 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5297 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5298 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5299 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5300 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5301 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5302 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5303 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5304 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5305 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5306 Component ID 211 Component ID: 211 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5307 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 - 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5308 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5309 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5310 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5311 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5312 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5313 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5314 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5315 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5316 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5317 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5318 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5319 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5320 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5321 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5322 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5323 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Module-Engine Control > Page 5324 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5331 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5332 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5333 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5334 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5335 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5336 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5337 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 Engine Control Module: Connector Views Module-Engine Control Component ID: 205 Component : MODULE-ENGINE CONTROL Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (5.9L) Pin Circuit Description 1 K139 18DB WASTEGATE SOLENOID CONTROL 2 G6 18VT/GY OIL PRESSURE SIGNAL 3-4 D65 18WT/LG CAN C BUS (+) 5 D64 18WT/LB CAN C BUS (-) 6 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 7 K20 18BR/GY GEN FIELD CONTROL 8 K314 18TN/YL TTVA MOTOR (+) 9-10 - 11 K923 18BR/WT WATER IN FUEL SENSOR GROUND 12 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 13 K615 18VT/WT INLET AIR TEMPERATURE SENSE 14 - 15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 16 K616 18BR/YL INLET AIR PRESSURE SENSE 17 K2 18VT/OR ECT SIGNAL 18 - 19 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER 20 K315 18TN/OR TTVA MOTOR (-) 21 K161 18BR/LB FAN SPEED SENSOR GROUND 22 K24 18BR/LB CKP SIGNAL 23 K200 18BR/YL SENSOR GROUND 24 K44 18DB/GY CMP SIGNAL 25 K668 18BR 5 VOLT SUPPLY 26 - 27 K853 18DB/BR 5 VOLT SUPPLY 28 - 29 K690 18BR/YL SENSOR GROUND 30 K11 16BR/YL INJECTOR CONTROL NO. 1 31 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 32 K944 18BK/GY CMP SENSOR GROUND 33 K167 18BR/YL APPS NO. 1 RETURN 34 N210 18DB/DG FAN SPEED SENSOR SIGNAL 35 - 36 K14 16BR/TN INJECTOR CONTROL NO. 4 37 - 38 - 39 - 40 K13 16TN INJECTOR CONTROL NO. 3 41 K210 18DB/TN SENSOR GROUND 42 K852 18BR/VT 5 VOLT SUPPLY 43 K37 18LB BOOST PRESSURE SENSOR SIGNAL 44 - 45 - 46 K58 16BR/VT INJECTOR CONTROL NO. 6 47 - 48 - 49 - 50 K12 16BR/DB INJECTOR CONTROL NO. 2 51 - 52 K975 18BR/OR CKP SENSOR GROUND 53 K915 18BR/WT FUEL RAIL SENSOR RETURN 54 F855 18PK/YL 5 VOLT SUPPLY 55 - 56 K38 16GY INJECTOR CONTROL NO. 5 57 K229 16TN/PK INJECTOR HIGH SIDE DRIVER-BANK 2 58 - 59 K227 16BR/LG INJECTOR HIGH SIDE DRIVER-BANK 1 60 - Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 Connector: Name : MODULE-ENGINE CONTROL C1 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 2 K682 18DB/WT EGR CONTROL NO. 1 3 K684 18DB/YL EGR CONTROL NO. 2 4 K686 18GY/DB EGR CONTROL NO. 3 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 5 K685 18DB EGR SIGNAL NO. 2 6-7 K161 18BR/LB FAN SPEED SENSOR GROUND 8-9 K670 18BR/LB EGR BYPASS VALVE SIGNAL 10 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN 11 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 12 - 13 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 14 K926 18DB/GY CRANKCASE SENSOR SIGNAL 15 K2 18VT/OR ECT SIGNAL 16 - 17 K671 18BR/DB EGR BYPASS STATUS 18 N27 18DB/GY FAN SPEED SENSOR SIGNAL 19 K37 18BR BOOST PRESSURE SENSOR SIGNAL 20 K616 18BR/YL INLET AIR PRESSURE SENSE 21 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 22 K971 18BR/PK SENSOR GROUND 23 - 24 K615 18VT/WT INLET AIR TEMPERATURE SENSE 25 K683 18DB/GY EGR SIGNAL NO. 1 26 K824 18DB/BR 5 VOLT SUPPLY 27 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 28 A804 18RD GEN SENSE 29 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 30 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 31 K24 18BR/LB CKP SIGNAL 32 G6 18VT/GY OIL PRESSURE SIGNAL 33 K972 18DB/TN ACTUATOR GROUND 34 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL 35 K687 18DB/LB EGR SIGNAL NO. 3 36 F855 18PK/YL 5 VOLT SUPPLY 37 K44 18DB/GY CMP SIGNAL 38 D130 18BR/VT ACTUATOR HIGH DATA LINK 39 D131 18WT/LG ACTUATOR LOW DATA LINK 40 K20 18BR/GY GEN FIELD CONTROL 41 K935 18DB EGR TEMPERATURE SENSOR SIGNAL 42 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 43 K541 18BR/VT TURBO SPEED SENSOR GROUND 44 K925 18BR/OR CKP SENSOR GROUND 45 K58 16BR/VT INJECTOR CONTROL NO. 6 46 K12 16BR/DB INJECTOR CONTROL NO. 2 47 K914 18BR/WT SENSOR GROUND 48 K916 18BR/OR SENSOR GROUND 49 - 50 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL 51 K613 16GY/BR INJECTOR HIGH SIDE DRIVER NO. 3 52 K612 16YL/BR INJECTOR HIGH SIDE DRIVER NO. 2 53 K611 16OR/BR INJECTOR HIGH SIDE DRIVER NO. 1 54 K14 16BR/TN INJECTOR CONTROL NO. 4 55 K38 16GY INJECTOR CONTROL NO. 5 56 K13 16TN INJECTOR CONTROL NO. 3 57 K11 16BR/YL INJECTOR CONTROL NO. 1 58 K658 16LG/BR INJECTOR HIGH SIDE DRIVER NO. 6 59 K638 16LB/BR INJECTOR HIGH SIDE DRIVER NO. 5 60 K614 16WT/BR INJECTOR HIGH SIDE DRIVER NO. 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 50 Qualifier : (5.9L) Pin Circuit Description 1-2-3 K23 18BR/WT APPS NO. 1 SIGNAL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 5 T515 18YL/DB TRANSMISSION CONTROL 6 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 7 K31 18BR FUEL PUMP CONTROL 8-9 T41 18YL/DB TRS T41 SIGNAL (P/N) 10 - 11 - 12 - 13 T6 18DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 14 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 15 T9 18DG/TN 3-4 SOLENOID CONTROL 16 - 17 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 18 - 19 - 20 A209 16RD FUSED B(+) 21 Z902 16BK GROUND 22 - 23 F856 18YL/PK 5 VOLT SUPPLY 24 K900 18DB/DG SENSOR GROUND 25 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 26 - 27 K312 18OR TTVA POSITION SENSOR SIGNAL 28 - 29 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL 30 A209 16RD FUSED B(+) 31 - 32 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 33 K854 18VT/BR 5 VOLT SUPPLY 34 - 35 K29 18WT/BR APPS NO. 2 SIGNAL 36 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 37 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 38 - 39 - 40 A209 16RD FUSED B(+) 41 C13 18LB/OR A/C CLUTCH CONTROL 42 - 43 K160 18BR/OR PWM FAN COIL SIGNAL 44 T14 18DG/BR OUTPUT SPEED SIGNAL 45 T13 18DG/VT SPEED SENSOR GROUND 46 V37 18VT S/C SWITCH NO. 1 SIGNAL 47 K25 18DB/VT BATT TEMP SIGNAL 48 K400 18BR/VT APPS NO. 2 RETURN 49 Z902 16BK GROUND 50 Z902 16BK GROUND Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 Connector: Name : MODULE-ENGINE CONTROL C2 Color : # of pins : 60 Qualifier : (6.7L) Pin Circuit Description 1 D65 18WT/LG CAN C BUS (+) 2 K31 18BR FUEL PUMP CONTROL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 5 G905 18BR/OR EXHAUST BRAKE SWITCH SIGNAL 6 V32 18VT/YL BRAKE SWITCH NO. 2 SIGNAL 7 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 8 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 9 K186 18BR/OR EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 10 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 11 - 12 - 13 - 14 - 15 T26 18DG/OR CLUTCH INTERLOCK/UPSTOP SWITCH OUTPUT 16 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 17 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 18 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 19 - 20 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 21 D64 18WT/LB CAN C BUS (-) 22 K400 18BR/VT APPS NO. 2 RETURN 23 - 24 K29 18WT/BR APPS NO. 2 SIGNAL 25 B29 18DG/WT BRAKE SWITCH NO. 1 SIGNAL 26 K854 18VT/BR 5 VOLT SUPPLY 27 K852 18BR/LB 5 VOLT SUPPLY 28 K167 18BR/DG APPS NO. 1 RETURN 29 K900 18DB/DG SENSOR GROUND 30 K25 18DB/VT BATT TEMP SIGNAL 31 D133 18WT/OR DIAGNOSTIC PORT HIGH DATA LINK 32 - 33 V937 18VT/BR S/C SWITCH RETURN 34 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 35 K23 18BR/WT APPS NO. 1 SIGNAL 36 - - 37 K128 18DG/LG REMOTE THROTTLE SIGNAL 38 - 39 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 40 V37 18VT S/C SWITCH NO. 1 SIGNAL 41 - 42 - 43 K348 18BR SMART POWER RELAY RETURN 44 C13 18LB A/C CLUTCH CONTROL 45 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 46 - 47 Z902 16BK GROUND 48 Z902 16BK GROUND 49 A209 16RD FUSED B(+) 50 A209 16RD FUSED B(+) 51 D132 18WT DIAGNOSTIC PORT LOW DATA LINK 52 - 53 - 54 G904 18VT/DG EXHAUST BRAKE LAMP SIGNAL 55 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 56 V38 18VT/OR S/C SWITCH NO. 2 SIGNAL 57 Z902 16BK GROUND 58 - 59 - 60 A209 16RD FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 Component ID 198 Component ID: 198 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 - 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5367 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5368 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5369 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5370 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5371 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5372 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 Component ID 211 Component ID: 211 Component : MODULE-POWERTRAIN CONTROL Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5378 Pin Circuit Description 123456789-10 11 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) 13 14 15 16 17 18 - 19 T160 20DG/WT SENSOR GROUND 20 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 21 22 23 24 25 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 29 A918 20RD FUSED B(+) 30 T751 20YL IGNITION START 31 - 32 33 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 38 Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5379 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5380 Connector: Name : MODULE-POWERTRAIN CONTROL C1 Color : BLACK/BLACK # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K98 18DB/YL COIL CONTROL NO. 8 2-3 K97 18DB/YL COIL CONTROL NO. 7 3 K97 18BR COIL CONTROL NO. 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5381 4 K28 18BR/LB INJECTOR CONTROL NO. 8 5 K26 18BR/YL INJECTOR CONTROL NO. 7 6-7-8-9 Z130 16BK/BR GROUND 10 A918 16RD FUSED B(+) 11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) 12 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 13 - 14 - 15 - 16 - 17 - 18 Z131 16BK/DG GROUND 19 Z951 16BK/YL GROUND 20 G6 16VT/GY OIL PRESSURE SIGNAL 21 - 22 - 23 - 24 A804 18RD/GY GEN SENSE 25 - 26 - 27 F856 20YL/PK 5 VOLT SUPPLY 28 K452 20BR/LB MDS SOL CONTROL NO. 4 29 A918 16RD FUSED B(+) 30 T751 20YL IGNITION START 31 K141 20DB/YL O2 1/2 SIGNAL 32 K902 20BR/DG O2 RETURN (UPSTREAM) 33 K243 20BR O2 2/2 SIGNAL 34 D65 20WT/LG CAN C BUS (+) 35 D64 20WT/LB CAN C BUS (-) 36 - 37 - 38 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5382 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5383 Connector: Name : MODULE-POWERTRAIN CONTROL C2 Color : BLACK/ORANGE # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 K10 18DB/OR COIL CONTROL NO. 6 2 K16 18DB/YL COIL CONTROL NO. 5 3 K15 18DB/GY COIL CONTROL NO. 4 4 K58 18BR/VT INJECTOR CONTROL NO. 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5384 5 K38 18BR/OR INJECTOR CONTROL NO. 5 6 K447 20TN/YL ETC MOTOR (+) 7 K18 18DB/OR COIL CONTROL NO. 3 8 K35 20DB/VT EGR SOL CONTROL 9 K17 18DB/TN COIL CONTROL NO. 2 10 K19 18DB/DG COIL CONTROL NO. 1 11 K14 18BR/TN INJECTOR CONTROL NO. 4 12 K13 18BR/LB INJECTOR CONTROL NO. 3 13 K12 18BR/DB INJECTOR CONTROL NO. 2 14 K11 18BR/YL INJECTOR CONTROL NO. 1 15 K922 20BR/DB TP SENSOR RETURN 16 K453 20BR/DG MDS SOL CONTROL NO. 6 17 K199 20BR/VT O2 2/1 HEATER CONTROL 18 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 19 K20 18BR/GY GEN FIELD CONTROL 20 K2 20VT/OR ECT SIGNAL 21 K22 20BR/OR TP NO. 1 SIGNAL 22 K34 20DB/LG EGR SIGNAL 23 K1 20VT/BR MAP SIGNAL 24 K942 20BR/LG KNOCK SENSOR NO. 1 RETURN 25 K42 20DB/YL KNOCK SENSOR NO. 1 SIGNAL 26 - 27 K900 20DB/DG SENSOR GROUND 28 K122 20BR/DG TP NO. 2 SIGNAL 29 F855 20PK/YL 5 VOLT SUPPLY 30 K21 20DB/LG IAT SIGNAL 31 K41 20DB/LB O2 1/1 SIGNAL 32 K904 20DB/DG O2 RETURN (DOWNSTREAM) 33 K43 20DB/LG O2 2/1 SIGNAL 34 K44 20DB/GY CMP SIGNAL 35 K24 20BR/LB CKP SIGNAL 36 K242 20BR/WT KNOCK SENSOR NO. 2 SIGNAL 37 K924 20WT/BR KNOCK SENSOR NO. 2 RETURN 38 K448 20TN/OR ETC MOTOR (-) Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5385 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5386 Connector: Name : MODULE-POWERTRAIN CONTROL C3 Color : BLACK/NATURAL # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1-2-3 K51 20BR/WT ASD CONTROL 4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5387 5 V35 20VT/OR S/C VENT SOL CONTROL 5 K454 20BR/OR MDS SOL CONTROL NO. 7 6 K451 20BR/WT MDS SOL CONTROL NO. 1 7 V32 20VT/YL SPEED CONTROL SUPPLY 8-9 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 10 K399 18BR/GY O2 2/2 HEATER CONTROL 11 C13 20LB/OR A/C CLUTCH CONTROL 12 V36 20VT/YL S/C VACUUM SOL CONTROL 13 - 14 V32 20VT/YL BRAKE SWITCH NO. 2 SIGNAL 15 V937 20VT/BR S/C SWITCH RETURN 16 K167 20BR/YL APPS NO. 1 RETURN 17 K400 20BR/VT APPS NO. 2 RETURN 18 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL 19 K342 16BR/WT ASD CONTROL OUTPUT 20 K52 20DB/WT EVAP PURGE SOL CONTROL 21 T41 20YL/DB TRS T41 SIGNAL (P/N) 22 G113 20VT PTO SENSE 22 G113 18PK/YL PTO SENSE 23 B29 20DG/WT BRAKE SWITCH NO. 1 SIGNAL 24 - 25 K23 20BR/WT APPS NO. 1 SIGNAL 26 - 27 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 28 K342 16BR/WT ASD CONTROL OUTPUT 29 K70 20DB/BR EVAP PURGE SOL SIGNAL 30 K66 20DB/WT P/S SWITCH SIGNAL 31 - 32 - 33 G24 20VT/BR OIL TEMPERATURE SIGNAL 34 V37 20VT S/C SWITCH NO. 1 SIGNAL 35 K107 20VT/WT ESM SIGNAL 36 K29 20WT/BR APPS NO. 2 SIGNAL 37 K31 20BR FUEL PUMP CONTROL 38 T752 20DG/OR STARTER SOLENOID CONTROL Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5388 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5389 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (DIESEL) Pin Circuit Description 1 T160 20YL/GY SENSOR GROUND 2 T259 20YL/DG 4C CONTROL 3- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5390 4 T140 20YL/GY MS CONTROL 56 T219 20YL/LG 2C CONTROL 78 T59 20YL/LB UD CONTROL 910 T20 20DG/BK L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z133 18BK/LG GROUND 13 Z133 18BK/LG GROUND 14 Z133 18BK/LG GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 24 25 26 T4 20DG/LB TRS T2 SIGNAL 27 T41 20YL/DB TRS T41 SIGNAL (P/N) 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5391 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5392 Connector: Name : MODULE-POWERTRAIN CONTROL C4 Color : BLACK/GREEN # of pins : 38 Qualifier : (GAS) Pin Circuit Description 1 T60 20YL/GY OD SOLENOID CONTROL 2 T259 20YL/DG 4C CONTROL 2 T59 20YL/LB UD CONTROL 3-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5393 4 T140 20YL/GY MS CONTROL 5-6 T219 20YL/LG 2C CONTROL 6 T19 18YL/DB 2/4 SOLENOID CONTROL 7-8 T59 20YL/LB UD CONTROL 9-10 T20 20DG/WT L/R CONTROL 11 T118 20DG LP VFS CONTROL 12 Z908 18BK GROUND 13 Z977 18BK GROUND 14 Z904 18BK GROUND 15 T1 20DG/LB TRS T1 SIGNAL 16 T3 20DG/DB TRS T3 SIGNAL 17 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 18 T515 20YL/DB TRANSMISSION CONTROL 19 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 20 T48 20BR/YL 4C PRESSURE SIGNAL 21 T29 20YL/WT UD PRESSURE SIGNAL 22 T9 20DG/TN OD PRESSURE SIGNAL 23 - 24 - 25 - 26 T4 20DG/LB TRS T2 SIGNAL 27 - 28 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 29 T50 20DG/PK L/R PRESSURE SIGNAL 30 T147 20DG/YL 2C PRESSURE SIGNAL 30 T47 18YL/DG 2/4 PRESSURE SIGNAL 31 T38 20YL/BR LINE PRESSURE SIGNAL 32 T14 20DG/BR OUTPUT SPEED SIGNAL 33 T52 20DG/OR INPUT SPEED SIGNAL 34 T13 20DG/VT SPEED SENSOR GROUND 35 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 36 - 37 T42 20DG/YL TRS T42 SIGNAL 38 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Component Location - 29 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5394 Component Location - 6 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel Engine Control Module: Description and Operation Engine Control Module (ECM) - Diesel Description DESCRIPTION CUMMINS FUEL SYSTEM COMPONENTS The Engine Control Module (ECM) for the 5.9L diesel engine (16) is bolted to the left side of the engine below the intake manifold. Operation OPERATION The main function of the Engine Control Module (ECM) is to electrically control the fuel system. The ECM also controls certain transmission and other functions previously controlled by the Powertrain Control Module (PCM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 5398 The ECM can adapt its programming to meet changing operating conditions. The ECM receives input signals from various switches and sensors. Based on these inputs, the ECM regulates various engine and vehicle operations through different system components. These components are referred to as ECM Outputs. The sensors and switches that provide inputs to the ECM are considered ECM Inputs. NOTE: ECM Inputs: - Accelerator Pedal Position Sensor (APPS) Signals #1 and #2 - AC system pressure - Auto shutdown (ASD) sense - Battery temperature - Battery temperature sensor - Battery voltage - Brake switch - Camshaft Position Sensor (CMP) - Crankshaft Position Sensor (CKP) - Data link connection for a scan tool - Engine Coolant Temperature (ECT) sensor - EATX module (if equipped) - Fuel level - Fuel pressure sensor - Fan speed (engine cooling fan) - Generator (battery voltage) output - Governor pressure (Auto. trans.) - Ground circuits - Inlet air temperature sensor/pressure sensor - Intake air temperature sensor/MAP sensor - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Key switch (ignition) - Oil Pressure switch - Overdrive switch (automatic transmission only) - Park/neutral switch (auto. trans. only) - Power ground - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Sensor return - Signal ground - Speed control multiplexed single wire input - Transfer case switch (4WD range position) - Transmission governor psi (automatic transmission only) - Transmission OSS (automatic transmission only) - Transmission oil pressure (automatic transmission only) - Transmission oil temperature (automatic transmission only) - Transmission throttle valve position (automatic transmission only) - Vehicle speed signal - Water-In-Fuel (WIF) sensor NOTE: ECM Outputs: After inputs are received by the ECM, certain sensors, switches and components are controlled or regulated by the ECM. These are considered ECM Outputs. These outputs are for: - A/C clutch relay - Auto shutdown (ASD) relay - Data link connection for diagnostic scan tool - Fan clutch PWM - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel control actuator - Fuel injector driver circuits - Fuel transfer (lift) pump - Generator field driver (-) - Generator field driver (+) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 5399 - Governor pressure (VFS solenoid) - Intake manifold air heater relays #1 and #2 control circuits - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oil pressure switch/warning lamp (databus) - Overdrive/3-4 shift solenoid (automatic transmission only) - SC source - SCI datalink bus (+) circuits - SCI datalink bus (-) circuits - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - TCC solenoid (automatic transmission only) - Transmission battery relay (automatic transmission only) - Transmission throttle valve actuator (automatic transmission only) - Transmission governor solenoid (automatic transmission only) - Wait-to-start warning lamp (databus) - Turbo wastegate solenoid - Water-In-Fuel (WIF) warning lamp (databus) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 5400 Engine Control Module: Description and Operation Powertrain Control Module - Description Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors Modes Of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 5401 IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD or O2S heater relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 5402 When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 5403 - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 Volt Supplies 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Ignition Circuit Sense IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). Power Grounds POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 5404 Sensor Return SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 5405 Engine Control Module: Description and Operation Powertrain Control Module - Operation Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - CAN C BUS (+) circuits - CAN C BUS (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for a scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module (ECM) - Diesel > Page 5406 - CAN C BUS (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for diagnostic scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission convertor clutch circuit. Driven through J1850 circuits. 5 Volt Supplies 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). Ignition Circuit Sense IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel Engine Control Module: Testing and Inspection Engine Control Module (ECM) - Diesel ECM/PCM PROGRAMMING MODULE REPROGRAMING Replacement ECM's will require programming utilizing the StarSCAN(R) or equivalent. The ECM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic ECM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN and StarMOBILE or equivalent Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. NOTE: For the Cummins Diesel, if the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. 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. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5409 6. Replace the ECM with the appropriate Generic ECM. 7. Program the ECM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the ECM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "ECM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 10. 10. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a ECM and/or TCM. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5410 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. 5. Replace the ECM with the appropriate Generic ECM. . 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select "More Options". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5411 c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the ECM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "ECM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle is equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the ECM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5412 Engine Control Module: Testing and Inspection PCM/ECM Programming ECM/PCM PROGRAMMING MODULE REPROGRAMING Replacement ECM's will require programming utilizing the StarSCAN(R) or equivalent. The ECM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic ECM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN and StarMOBILE or equivalent Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. NOTE: For the Cummins Diesel, if the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. 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. 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. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5413 6. Replace the ECM with the appropriate Generic ECM. 7. Program the ECM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 8. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 9. b. No >> go to STEP 10. 9. Program the ECM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "ECM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 10. 10. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a ECM and/or TCM. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5414 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the ECM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash ECM" screen for later reference. 5. Replace the ECM with the appropriate Generic ECM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select "More Options". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5415 c. Select "ECU Flash". d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash ECM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the ECM to the Wireless Control Module (WCM). Using the StarSCAN at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "ECM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the ECM. a. Scroll through the list of controllers and highlight the ECM. b. Select "Misc. Function". c. Highlight "Check ECM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle is equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the ECM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the ECM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the ECM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5416 Engine Control Module: Testing and Inspection SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED , ECM REPLACED , WCM REPLACED , or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5417 SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5418 Engine Control Module: Testing and Inspection Powertrain Control Module PCM/ECM REPROGRAMMING - GAS MODULE REPROGRAMING Replacement PCM's will require programming utilizing the StarSCAN(R) or equivalent. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. SPECIAL TOOLS/EQUIPMENT OR EQUIVALENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN(R) or equivalent diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) or equivalent for your dealership's network. For instruction on setting up your StarSCAN(R) or equivalent for the dealer's network; refer to the StarSCAN(R) or equivalent Quick Start Networking Guide available on DealerCONNECT > Service > StarSCAN(R) or equivalent and StarMOBILE Tools > Online Documentation. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9410 StarSCAN(R) or equivalent ethernet cable to the StarSCAN(R) or equivalent and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 4. Power ON the StarSCAN(R) or equivalent. 5. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 6. Replace the PCM with the appropriate Generic PCM. 7. Program the PCM as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File". Follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 5. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 8. Is this a GPEC Module? a. Yes >> go to STEP 9. b. No >> go to STEP 12. 9. Do not start the engine prior to completing the following steps (a. and b.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5419 a. Turn the ignition switch to the OFF position for no less than 15 seconds. b. Turn the ignition to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds. 10. Is this vehicle equipped with a CVT? a. Yes >> go to STEP 11. b. No >> go to STEP 17. 11. The TCM must be reprogrammed as follows: a. Using the StarSCAN(R) or equivalent at the "Home" screen, Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash TCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. NOTE: If the part number recorded in step "11e" is the same as the new p/n shown on the "Flash File List" screen no further action is required. Cancel the TCM reprogram procedure. Continue to step STEP 17. g. Highlight the appropriate calibration. h. Select "Download to Scantool". i. Select "Close" after the download is complete, then select "Back". j. Highlight the listed calibration. k. Select "Update Controller". Follow on screen instructions. l. When the update is complete, select "OK". m. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number. n. Continue to step STEP 15 12. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 13. b. No >> go to STEP 14. 13. Program the PCM to the Wireless Control Module (WCM). a. Highlight the WCM. b. Select "Misc. Function". c. Highlight "PCM Replaced". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. f. When complete proceed to STEP 15. 14. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 15. Is the vehicle equipped ETC? a. Yes >> go to STEP 17. b. No >> go to STEP 16. 16. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select ECU View b. Scroll through the list of controllers and highlight the PCM. c. Select Misc. Function. d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select Next after each step. Select Finish after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the Home screen select System View. Then select All DTCs. Press Clear All Stored DTCs if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 17. Type the necessary information on the Authorized Modification Label p/n 04275086AB and attach near the VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5420 REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. NOTE: For detailed information on the operation of the StarSCAN(R) or equivalent, refer to the Quick Reference documentation provided in the StarSCAN(R) or equivalent documentation kit. Look under Training Aids and also under Download Center > Frequently Asked Questions for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger timer to maintain the charging voltage for the duration of the flash process. 2. Connect the CH9404 StarSCAN(R) or equivalent vehicle cable to the StarSCAN(R) or equivalent and the vehicle. 3. Power ON the StarSCAN(R) or equivalent. 4. Retrieve the old ECU part number. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. 5. Replace the PCM with the appropriate Generic PCM. 6. Insert the StarSCAN(R) or equivalent Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) or equivalent Software Update CD will start automatically. Select "Download Flash Updates". 7. At the "Select a method for looking up controller flash updates. " screen: a. Select "Enter part number". Enter the "Part Number" recorded in STEP 4 when prompted to do so. b. Using the mouse highlight the appropriate "Calibration". Select "Next". c. Follow the on screen instructions. d. When completed, proceed to STEP 8. 8. With the StarSCAN(R) or equivalent powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) or equivalent USB port. 9. Connect the StarSCAN(R) or equivalent to the vehicle (if not already connected). 10. Power ON the StarSCAN(R) or equivalent. 11. Download the flash file from the USB key to the StarSCAN(R) or equivalent. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "Flash Download", then select "Retrieve files from the USB storage device" b. Highlight the appropriate calibration. Select "Download to Scan Tool" c. When the download is complete, select "Close" and "Back". 12. Reprogram the ECU. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View". b. Select More Options". c. Select "ECU Flash". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Engine Control Module (ECM) - Diesel > Page 5421 d. Highlight the appropriate calibration. e. Select "Update Controller". Follow the on screen instructions. f. When the update is complete, select "OK". g. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. 13. Is "WCM - Wireless Control Module" displayed in the "ECU Overview" screen list of modules? a. Yes >> go to STEP 14. b. No >> go to STEP 15. 14. Program the PCM to the Wireless Control Module (WCM). Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the WCM. c. Select "Misc. Function". d. Highlight "PCM Replaced". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. g. When complete proceed to STEP 16. 15. Program the VIN into the PCM. a. Scroll through the list of controllers and highlight the PCM. b. Select "Misc. Function". c. Highlight "Check PCM VIN". d. Select "Start" e. Follow the on screen instructions. Select "Next" after each step. When the window appears with 17 boxes, select "Show Keyboard". Place the cursor to the right of the last box and then backspace to delete the boxes from the window. Enter the VIN. Select "Finish" after completing the last step. f. Unplug the scan tool from the Data Link Connector. g. At the "Vehicle Disconnected" screen, press "OK". h. Connect the scan tool to the Data Link Connector and verify that the VIN is visible at the top of the "Home" screen. 16. Is the vehicle equipped with a 3.7L or 4.7L engine? a. Yes >> go to STEP 18. b. No >> go to STEP 17. 17. Using the StarSCAN(R) or equivalent at the "Home" screen: a. Select "ECU View" b. Scroll through the list of controllers and highlight the PCM. c. Select "Misc. Function". d. Highlight "Learn ETC". e. Select "Start" f. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "ECU View" from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 18. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. ** Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel Engine Control Module: Service and Repair Engine Control Module (ECM) - Diesel 5.9L Diesel 5.9L DIESEL CUMMINS FUEL SYSTEM COMPONENTS The Engine Control Module (ECM) (16) is bolted to a support bracket near the fuel filter. The support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. 3. Remove the 50-way and 60-way connector bolts at the ECM. Note: The connector bolt is a female allen head. As bolt is being removed, very carefully remove connectors from the ECM. 4. Remove five ECM mounting bolts and remove ECM from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 5424 6.7L Diesel 6.7L DIESEL The Engine Control Module (ECM) (5) is located on the left side of the engine. A support bracket mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other end of the wire is fastened to the engine block. 1. Record any Diagnostic Trouble Codes (DTC's) found in the ECM. To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must be disconnected before unplugging ECM connectors. 2. Disconnect both negative battery cables at both batteries. Access to the ECM is easier by working through the left front wheel opening. 3. Remove left front wheel. 4. Remove plastic left front fender splash shield. 5. Remove electrical connector bolts at ECM. Note: As each bolt is being removed, very carefully remove connectors from the ECM. 6. Remove three ECM mounting bolts (6) and remove ECM from engine. 5.9L Diesel 5.9L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 5425 CUMMINS FUEL SYSTEM COMPONENTS Do not apply paint to ECM or a poor ground will result. 1. Position the ECM (16) to the ECM support bracket and install the five mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pin connectors in ECM, 50-way and 60-way connectors for corrosion or damage. Repair as necessary. 3. Clean pins in the 50-way and 60-way electrical connectors with a electrical contact cleaner. 4. Install the 50-way and 60-way connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Reconnect both negative battery cables. 6. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM. 6.7L Diesel 6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 5426 Do not apply paint to ECM or a poor ground will result. 1. Position ECM (5) to the ECM support bracket and install mounting bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 2. Check pins in electrical connectors for corrosion, damage or dirt intrusion. Also check all pins for being bent. Repair as necessary. Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTC's. 3. Clean pins in electrical connectors with an electrical contact cleaner. 4. Install connectors to ECM. Tighten connector bolts to 3 Nm (27 in. lbs.). 5. Install splash shield. 6. Install left front wheel. 7. Connect both negative battery cables. 8. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC's) from ECM.FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 5427 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 5428 Engine Control Module: Service and Repair Powertrain Control Module - Removal REMOVAL CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (4) and remove PCM from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Engine Control Module (ECM) - Diesel > Page 5429 Engine Control Module: Service and Repair Powertrain Control Module - Installation INSTALLATION CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The scan tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5433 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5434 Main Relay (Computer/Fuel System): Diagrams Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5435 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5436 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5437 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Diagrams Oxygen Sensor Relay: Diagrams 2007-2009 Ram truck, 6.7L, use an O2 module for oxygen sensor heater control. The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5445 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5446 Accelerator Pedal Position Sensor: Diagrams Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5447 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 5450 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 5453 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5457 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5458 Air Flow Meter/Sensor: Diagrams Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5459 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5460 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 5463 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5467 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5468 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5469 Battery Temperature Sensor: Diagrams Component ID: 403 Component : SENSOR-BATTERY TEMPERATURE Connector: Name : SENSOR-BATTERY TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K25 20DB/VT BATT TEMP SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5470 Component Location - 30 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 5471 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Description DESCRIPTION The Battery Temperature Sensor (BTS) is used only on the diesel engine. It is attached to the battery tray located under the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation > Battery Temperature Sensor - Description > Page 5474 Battery Temperature Sensor: Description and Operation Battery Temperature Sensor - Operation OPERATION The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and O2 sensor heater tests). Most OBD II monitors are disabled below 20°F. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Removal REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Service and Repair > Battery Temperature Sensor - Removal > Page 5477 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor - Installation INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5481 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5482 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5483 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5484 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5485 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5486 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5487 Camshaft Position Sensor: Diagrams Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5488 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5489 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5490 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5491 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5492 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5493 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 5496 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor o-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 5499 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor o-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5503 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5504 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5505 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5506 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5507 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5508 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5509 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component ID: 410 Component : SENSOR-ENGINE COOLANT TEMPERATURE Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (DIESEL) A K200 18BR/YL SENSOR GROUND A K914 18BK/WT SENSOR GROUND B K2 18VT/OR ECT SIGNAL Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5510 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5511 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5512 Connector: Name : SENSOR-ENGINE COOLANT TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K2 20VT/OR ECT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5513 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5514 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 5515 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 5520 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) for the CKP is located behind the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 5523 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5527 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5528 Crankcase Pressure Sensor: Diagrams Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 5529 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5534 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5535 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5536 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5537 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5538 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5539 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5540 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5541 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5544 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5545 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5546 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5547 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5548 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5549 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5550 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5551 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 5554 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 5557 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5562 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5563 Exhaust Pressure Sensor: Locations Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5564 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5565 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5566 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Locations > Sensor-Exhaust Pressure 1/1 > Page 5567 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/1 Component ID: 412 Component : SENSOR-EXHAUST PRESSURE 1/1 Connector: Name : SENSOR-EXHAUST PRESSURE 1/1 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K355 18BR/DG EXHAUST PRESSURE SENSOR SIGNAL Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5570 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5571 Exhaust Pressure Sensor: Diagrams Sensor-Exhaust Pressure 1/2 Component ID: 413 Component : SENSOR-EXHAUST PRESSURE 1/2 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 18BR/VT APPS NO. 2 RETURN 2 K182 18BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 18VT/BR 5 VOLT SUPPLY Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5572 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5573 Connector: Name : SENSOR-EXHAUST PRESSURE 1/2 Color : # of pins : 3 Qualifier : (6.7L) Pin Circuit Description 1 K400 20BR/VT APPS NO. 2 RETURN 2 K182 20BR/WT EXHAUST PRESSURE 1/2 SENSOR SIGNAL 3 K854 20VT/BR 5 VOLT SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5574 Component Location - 25 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Diagrams > Sensor-Exhaust Pressure 1/1 > Page 5575 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5579 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5580 High Idle Switch: Diagrams Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Locations > Page 5581 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5586 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5587 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5588 Intake Air Temperature Sensor: Connector Locations Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5589 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5590 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5591 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5592 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5593 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 5594 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor Intake Air Temperature Sensor: Diagrams Intake Air Temperature Sensor Component ID: 421 Component : SENSOR-INTAKE AIR TEMPERATURE Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : BLACK # of pins : 2 Qualifier : (6.7L DH) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5597 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5598 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5599 Connector: Name : SENSOR-INTAKE AIR TEMPERATURE Color : DK. GRAY # of pins : 2 Qualifier : (GAS) Pin Circuit Description 1 K21 20DB/LG IAT SIGNAL 2 K900 20DB/DG SENSOR GROUND Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5600 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5601 Component Location - 7 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5602 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5603 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-MAP Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5604 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5605 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5606 Intake Air Temperature Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5607 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5608 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5609 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5610 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5611 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Intake Air Temperature Sensor > Page 5612 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 5613 Intake Air Temperature Sensor: Description and Operation OPERATION The Inlet Air Temperature/Pressure Sensor is a combination dual-function sensor. The sensor element extends into the intake air stream at the top of the air filter housing. Ambient air temperature as well as barometric pressure is monitored by this sensor. The Engine Control Module (ECM) monitors signals from this sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL The Inlet Air Temperature/Pressure Sensor (3) is located on the air cleaner cover. 1. Disconnect electrical connector (7) at sensor. 2. Remove mounting screw (2). 3. Remove sensor from air cleaner cover. 4. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 5616 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor (3) into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (2). 4. Install electrical connector (7). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5621 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5622 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5623 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5624 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5625 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5626 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5627 Manifold Pressure/Vacuum Sensor: Locations Sensor-Temperature/Pressure-Map Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5628 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Sensor-Temperature/Pressure-Inlet > Page 5629 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Inlet Component ID: 441 Component : SENSOR-TEMPERATURE/PRESSURE-INLET Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (5.9L) Pin Circuit Description 1 K690 18BR/YL SENSOR GROUND 2 K615 18VT/WT INLET AIR TEMPERATURE SENSE 3 K668 18BR 5 VOLT SUPPLY 4 K616 18BR/YL INLET AIR PRESSURE SENSE Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5632 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5633 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5634 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-INLET Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K616 18BR/YL INLET AIR PRESSURE SENSE 2 F855 18PK/YL 5 VOLT SUPPLY 3 K615 18VT/WT INLET AIR TEMPERATURE SENSE 4 K916 18BR/OR SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5635 Component Location - 4 Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5636 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5637 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5638 Manifold Pressure/Vacuum Sensor: Diagrams Sensor-Temperature/Pressure-Map Component ID: 442 Component : SENSOR-TEMPERATURE/PRESSURE-MAP Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : BLACK # of pins : 4 Qualifier : (5.9L) A K210 18DB/TN SENSOR GROUND B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL C F855 18PK/YL 5 VOLT SUPPLY D K37 18LB BOOST PRESSURE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5639 Connector: Name : SENSOR-TEMPERATURE/PRESSURE-MAP Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K37 18BR BOOST PRESSURE SENSOR SIGNAL 2 F855 18PK/YL 5 VOLT SUPPLY 3 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL 3 K735 18BR/LG CHARGE AIR COOLER OUTLET TEMPERATURE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Sensor-Temperature/Pressure-Inlet > Page 5640 4 K916 18BR/OR SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Air Pressure (MAP) Sensor Manifold Pressure/Vacuum Sensor: Description and Operation Manifold Air Pressure (MAP) Sensor DESCRIPTION A combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is used. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Manifold Air Pressure (MAP) Sensor > Page 5643 Manifold Pressure/Vacuum Sensor: Description and Operation Sensor-Temperature/Pressure-MAP OPERATION The combination, dual function Intake Manifold Air Temperature Sensor/MAP Sensor is installed into the top of the intake manifold with the sensor element extending into the air stream. The IAT portion of the sensor provides an input voltage to the Engine Control Module (ECM) indicating intake manifold air temperature. The MAP portion of the sensor provides an input voltage to the ECM indicating turbocharger boost pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (4) sensor is installed into the top of the intake manifold. 1. Clean area around sensor. 2. Disconnect electrical connector (3) from IAT/MAP sensor. 3. Remove mounting screw (5). 4. Remove sensor from intake manifold. 5. Check condition of sensor O-ring. Removal-Pick Up Models REMOVAL-PICK UP MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Clean area around sensor. 2. Disconnect electrical connector (2) from IAT/MAP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5646 3. Remove mounting screw (4). 4. Remove sensor from manifold. 5. Check condition of sensor O-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5647 Manifold Pressure/Vacuum Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold cover with clean engine oil. 4. Position sensor (4) into intake manifold. 5. Install and tighten sensor mounting screw (5) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (3) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The combination, dual function Intake Manifold Air Temperature Sensor/MAP (IAT/MAP) (3) sensor is installed into the intake air connection manifold, below, and to the rear of the EGR valve (5). 1. Check condition of sensor O-ring. 2. Clean sensor mounting area at intake manifold. 3. Lubricate sensor O-ring and sensor mounting hole in intake manifold with clean engine oil. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 5648 4. Position sensor (3) into intake manifold. 5. Install and tighten sensor mounting screw (4) to 1 Nm (9 in. lbs.) torque. 6. Connect electrical connector (2) to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5657 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5658 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5659 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5660 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5661 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5662 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5663 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5669 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5670 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5671 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5681 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5682 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5683 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5688 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5689 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5690 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5691 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5692 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5693 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5694 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 08-035-08 > Nov > 08 > Engine Controls - Oxygen Sensor Testing Information Oxygen Sensor: All Technical Service Bulletins Engine Controls - Oxygen Sensor Testing Information NUMBER: 08-035-08 GROUP: Electrical DATE: November 21, 2008 SUBJECT: Proper Testing Tools For Oxygen Sensor Terminals OVERVIEW: This bulletin describes the use of proper test probes to test the Oxygen (02) Sensor connector terminals equipped with the new TP2 style of sensor. MODELS: 2007-2009 (DH) 2500 Pick Up 2007-2009 (D1) 3500 Pick Up NOTE: This bulletin applies to models equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: The new TP2 style 02 sensors have smaller terminals that may be damaged (spread) when using standard Digital Volt Ohm Meter (DVOM) test probes. The recommended tool for these testing procedures is the Miller Tool # 6801 (Fig. 1) Two (2) of these probes are required when performing circuit tests as described in DealerCONNECT. The tool was originally included as part of Miller Tool # 6807 and # 8197A. Each of these kits contained one (1) # 6801 terminal probe. Two (2) additional Miller test probes # 6801 will be delivered to affected Dodge dealers shortly. Two (2) new terminal probes (# 6801) will be included and shipped as kit # 10190. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 NUMBER: 18-035-08 GROUP: Vehicle Performance DATE: September 13, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.02 OR HIGHER. StarMOBILE DESKTOP CLIENT - OR - StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: MIL Illumination Due to P2000, P2A00 and/or P2A01 OVERVIEW: This bulletin involves verifying all TSB's related to high sooting issues have been properly addressed, replacing both Oxygen (02) Sensors, and wrapping the exhaust pipe in the area of the FRONT 02 sensor. This bulletin also involves verifying that the Documentation Kit has been installed in the vehicle and the customer has been informed of its contents. MODELS: 2007 - 2008 (DH/D1) Ram Truck 2500/3500 NOTE: This bulletin applies to vehicles equipped with a 6.7L Cummins diesel engine (sales code ETJ). SYMPTOM/CONDITION: Customer may experience MIL illumination. Further investigation by the technician may find one or more of the following DTC(s) present: ^ P2000 - NOX Absorber Efficiency Below Threshold - Bank 1. ^ P2A00 - 02 Sensor 1/1 Circuit Performance. ^ P2A01 - 02 Sensor 1/2 Circuit Performance. DIAGNOSIS: If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Refer to TSB's related to turbocharger and DPF repairs (11-002-07,11-001-08,11 -002-08 and 18-013-08) if needed. NOTE: ECM (PCM) software commands when and what the CCN will display on the EVIC regarding the new engine system and exhaust aftertreatment system messages. The ECM software must be up to date (correct software level) in order for the new EVIC messages to display as designed and to address the symptoms and conditions above. ^ Verify software level in ECM and CCN is at the latest software level available in DealerCONNECT. ^ Verify DTC's other than those listed in the SYMPTOM/CONDITION should be addressed with the appropriate TSB or Service Procedures available in DealerCONNECT. ^ IF making a Diesel Particulate Filter (DPF) or turbocharger repair in conjunction with this TSB, ensure EGR system, Turbo, Intake, Charge Air Cooler, and other sensors are inspected and cleaned as described in these TSB's. Systems should be cleaned to "Like New" condition. Vehicles that have excess soot build up should have the source of the soot build up diagnosed and repaired prior to proceeding with this bulletin. ^ Verify proper maintenance has been performed, including: fuel and air filter brand (Mopar recommended) and condition. ^ Check Crankcase Ventilation (CCV) system for restriction which may cause oil infiltration into turbo and intake system. ^ Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. If any of the DTC's listed in the SYMPTOM/CONDITION are present and the conditions listed above have been met, perform the REPAIR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5704 PROCEDURE. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and replace both Oxygen Sensors with p/n 05149263AA. Torque to 41 N.m (30 ft.lbs). Connect wiring to both of the Oxygen (02) sensors. NOTE: Do not use earlier versions of 02 sensor when performing this repair. Ensure part number is 05149263AA or higher level. 2. Using scissors or a utility knife, cut exhaust wrap to a length of 12.5 (3.8 m). 3. Locate the Diesel Oxidation Catalyst (DOC) downpipe to NOx Absorber Catalyst (NAC) flange. Measure and mark a line at a distance of 7 (18 cm) in front of this flange (Fig. 1). 4. Loosely install band clamps; a. One in front of 02 sensor. b. One between DOC-to-NAC flange and 02 sensor. NOTE: Do not wrap or cover wiring for oxygen sensor or temperature sensor with insulation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5705 5. Starting about 1" (25 mm) in front of the (DOC)-to-(NAG) flange and using full overlap, wrap insulation once around the exhaust pipe (Fig. 2). 6. Wrap pipe in an upstream direction (toward 02 sensor) using a 1" (25 mm) over lap. Wrap to the 02 sensor. Wrap the body of the 02 sensor two times. 7. Then continue wrapping the exhaust pipe in an upstream direction to the 7 (17.75cm) mark established in Step # 3. 8. Now continue the exhaust pipe wrap in a downstream direction and slalom around sensor. This time, do not wrap the insulation around the body of the 02 sensor. Continue to the wrap until you reach the (DOC)-to-(NAC) flange (Fig. 3). 9. Slide a band clamp over each end of the wrap. 10. Tighten both clamps. One at front of wrap and one at rear of wrap. 11. If a complete Documentation Kit has not been installed on the vehicle, install the Documentation Kit now. (Kit is zero cost). a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD in the vehicle Glove Box. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > 18-035-08 > Sep > 08 > Engine Controls - MIL ON/DTC's P2000/P2A00/P2A01 > Page 5706 c. Place the Informational CD in the vehicle's CD player, (if equipped). d. Install the new Sun Visor Label on the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. e. Dealer personnel should inform the customer the Documentation Kit has been installed on the vehicle and advise the customer to familiarize themselves with this information. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5716 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5717 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5718 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5719 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5720 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5721 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oxygen Sensor: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 5722 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Oxygen Sensor: Locations Sensor - Oxygen 1/1 Component ID: 431 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5725 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5726 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5727 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5728 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5729 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5730 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5731 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5732 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 Z42 20BK/LG GROUND 3 K902 20BR/DG O2 RETURN (UPSTREAM) 4 K41 20DB/LB O2 1/1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5733 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5734 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5735 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5736 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5737 Oxygen Sensor: Locations Sensor - Oxygen 1/2 Component ID: 432 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5738 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5739 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5740 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5741 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5742 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5743 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 2 Z43 20BK/LB GROUND 3 K904 20DB/DG O2 RETURN (DOWNSTREAM) 4 K141 20DB/YL O2 1/2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5744 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5745 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 5746 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor Oxygen Sensor: Diagrams Module-O2 Sensor Component ID: 209 Component : MODULE-O2 SENSOR Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 3 D132 20WT DIAGNOSTIC PORT LOW DATA LINK 4 K141 20DB/YL O2 1/2 SIGNAL 5 K734 20BR/DG 02 1/2 PUMP CURRENT 6 K41 20DB/LB O2 1/1 SIGNAL 7 K89 20BR/LG 02 1/1 PUMP CURRENT 8 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 9 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 10 Z902 20BK GROUND 11 D133 20WT/OR DIAGNOSTIC PORT HIGH DATA LINK 12 K904 20DB/DG O2 1/2 RETURN 13 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 14 K902 20BR/DG O2 1/1 RETURN 15 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 16 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN Connector: Name : MODULE-O2 SENSOR Color : # of pins : 16 Qualifier : (6.7L DIESEL) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5749 Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 3 D132 20WT DIAGNOSTIC PORT LOW DATA LINK 4 K141 20DB/YL O2 1/2 SIGNAL 5 K734 20BR/DG 02 1/2 PUMP CURRENT 6 K41 20DB/LB O2 1/1 SIGNAL 7 K89 20BR/LG 02 1/1 PUMP CURRENT 8 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 9 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) 10 Z902 20BK GROUND 11 D133 20WT/OR DIAGNOSTIC PORT HIGH DATA LINK 12 K904 20DB/DG O2 1/2 RETURN 13 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 14 K902 20BR/DG O2 1/1 RETURN 15 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 16 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5750 Oxygen Sensor: Diagrams Sensor-Oxygen 1/1 Component ID: 431 Component : SENSOR-OXYGEN 1/1 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5751 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5752 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5753 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5754 Connector: Name : SENSOR-OXYGEN 1/1 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K89 20BR/LG 02 1/1 PUMP CURRENT 2 K902 20BR/DG O2 1/1 RETURN 3 K79 20BR/LB O2 1/1 HEATER CONTROL RETURN 4 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5755 5 K103 20BR/LB O2 1/1 PUMP CELL CURRENT TRIM 6 K41 20DB/LB O2 1/1 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5756 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5757 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5758 Connector: Name : SENSOR-OXYGEN 1/1 Color : BLACK # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K99 20BR/LG O2 1/1 HEATER CONTROL SUPPLY 2 Z42 20BK/LG GROUND 3 K902 20BR/DG O2 RETURN (UPSTREAM) 4 K41 20DB/LB O2 1/1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5759 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5760 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5761 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5762 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5763 Oxygen Sensor: Diagrams Sensor-Oxygen 1/2 Component ID: 432 Component : SENSOR-OXYGEN 1/2 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5764 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5765 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5766 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 6 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K734 20BR/DG 02 1/2 PUMP CURRENT 2 K904 20DB/DG O2 1/2 RETURN 3 K80 20BR/TN O2 1/2 HEATER CONTROL RETURN 4 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5767 5 K733 20BR O2 1/2 PUMP CELL CURRENT TRIM 6 K141 20DB/YL O2 1/2 SIGNAL Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5768 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5769 Connector: Name : SENSOR-OXYGEN 1/2 Color : # of pins : 4 Qualifier : (GAS) Pin Circuit Description 1 K299 20BR/WT O2 1/2 HEATER CONTROL SUPPLY 2 Z43 20BK/LB GROUND 3 K904 20DB/DG O2 RETURN (DOWNSTREAM) 4 K141 20DB/YL O2 1/2 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5770 Component Location - 21 Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5771 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Module-O2 Sensor > Page 5772 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Pick Up Models Oxygen Sensor: Description and Operation Description - Pick Up Models DESCRIPTION - PICK UP MODELS The two oxygen (O2) sensors (1) and (2) are located at each end of the #2 catalyst. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Pick Up Models > Page 5775 Oxygen Sensor: Description and Operation Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream (1), and 1/2 downstream (2). A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Pick Up Models > Page 5776 Oxygen Sensor: Description and Operation Oxygen Sensor Module Description - Pick Up Models DESCRIPTION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). Operation - Pick Up Models OPERATION - PICK UP MODELS Two different six-wire O2 sensors are used. These sensors are titled 1/1 upstream, and 1/2 downstream. A separate O2 Sensor Module (1) is also used. The engine aftertreatment system monitors the O2 content in the diesel engine exhaust. The ECM monitors the exhaust gases for oxygen content and varies the rich/lean fuel mixture of the intake air fuel mixture to adjust the system. This diagnostic monitors the status message broadcast by the O2 Sensor Module (1) for the upstream O2 sensor's internal heater circuit. The ECM will set the fault if it receives a FMI (Failure Mode Indicator) message from the O2 Sensor Module. The ECM will illuminate the MIL lamp immediately when the diagnostic runs and fails. The ECM will turn off the MIL lamp diagnostic runs and passes in four consecutive drive cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module Oxygen Sensor: Service and Repair Oxygen Sensor Module Removal - Pick Up Models REMOVAL - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Raise and support vehicle. 2. Disconnect electrical connector (2) at module (1). 3. Remove four bolts (3). 4. Remove module from frame rail. Installation - Pick Up Models INSTALLATION - PICK UP MODELS The oxygen sensor module (1) is located under the vehicle. It is bolted to the outer side of right frame rail (4). 1. Position module (1) to frame rail (4). 2. Install four bolts (3). 3. Tighten bolts (3) to 6 Nm (53 in. lbs.) torque. 4. Connect electrical connector (2) to module (1). 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5779 Oxygen Sensor: Service and Repair Removal REMOVAL - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converters become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support vehicle. 2. Disconnect main wire connector from O2S sensor pigtail harness. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in catalytic convertor using appropriate tap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Oxygen Sensor Module > Page 5780 Oxygen Sensor: Service and Repair Installation INSTALLATION - PICK UP MODELS The two oxygen (O2) sensors 1/1 (1) and 1/2 (2) are located at each end of the #2 catalyst. Threads of NEW oxygen sensors are factory coated with anti-seize compound to aid in removal.DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. Be careful not to get anti-seize compound on sensor tip. 1. Install O2S sensor. Tighten to 41 Nm (30 ft. lbs.) torque. 2. Connect O2S sensor pigtail harness to main wire harness connector. 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 5785 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5790 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5791 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5792 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5793 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5794 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5795 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5796 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5797 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5798 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5799 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5800 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5803 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5804 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5805 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5806 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5807 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5808 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5809 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5810 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5811 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5812 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5813 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 5816 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 5817 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 5818 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 5819 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 5822 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 5823 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 5824 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 5825 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5850 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5851 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5852 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5853 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5854 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5855 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5856 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5857 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5858 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5859 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 5860 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5863 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5864 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5865 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5866 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5867 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5868 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5869 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5870 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5871 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5872 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 5873 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 5876 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 5877 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 5878 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 5879 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 5882 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 5883 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 5884 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 5885 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5912 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5913 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5914 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5915 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5916 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5917 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5918 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 5919 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5922 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5923 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5924 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5925 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5926 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5927 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5928 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 5929 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 5932 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 5935 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). PRESSURE DIFFERENTIAL TUBING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 5942 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 5943 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION PRESSURE DIFFERENTIAL TUBING 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 5944 NOTE: Make sure there is not a dip in the pressure differential hoses. 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): Customer Interest Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 5953 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Customer Interest for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 5954 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F Diesel Particle Filter (DPF): All Technical Service Bulletins Engine Controls - MIL ON/DTC's P1451/P200C/P242F NUMBER: 11-001-09 GROUP: Exhaust DATE: July 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-002-07, DATED SEPTEMBER 25, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Diesel Particulate Filter - Diagnosis and Repair of DTC's P1451, P200C, P242F or Black Smoke From Exhaust OVERVIEW: This bulletin provides revised diagnostic and repair procedures for DTC's P1451, P2OOC, P242F, black smoke from the exhaust, or a no start condition due to a nonfunctional or plugged Diesel Particulate Filter (DPF). The Mobile DeSoot procedure initiated by the service tool will soon be replaced with a new Stationary DeSoot procedure. The stationary DeSoot procedure will only work when a vehicle needs to have a DeSoot performed, such as is indicated by the presence of an active P1451. A Service Bulletin will be released when this procedure becomes available. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ). SYMPTOM/CONDITION: The customer may experience a Malfunction Indicator Lamp (MIL) illumination, warning chime and an overhead Electronic Vehicle Information Center (EVIC) message regarding the aftertreatment system and/or black smoke from the exhaust and/or a no start condition. Further Investigation by the technician may reveal that the MIL illumination and/or EVIC message is due to one or more of the following Diagnostic Trouble Codes (DTC's): ^ P1451 - Diesel Particulate Filter - System Performance. ^ P242F - Diesel Particulate Filter Restriction - Ash Accumulation. ^ P200C - Diesel Particulate Filter Over Temperature - Bank 1. NOTE: While the wiTECH tool is the preferred method of testing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTCs" tab. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 5960 It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. 5. Are DTC's P242F and/or P200C present, either active or stored, in the PCM, or does the vehicle have visible black smoke from the exhaust or a no start condition caused by a restricted exhaust? a. If YES >> then the Diesel Particulate Filter (DPF) may require replacement. Proceed to REPAIR PROCEDURE B: DPF Repair Procedure. b. If NO >> then proceed to Step # 6. 6. Is DTC P1451 ACTIVE in the PCM (but DTC's P242F and/or P200C are NOT present and there is no black smoke concern)? a. If YES >> then a Scan Tool initiated DeSoot is required for the DPF. Proceed to REPAIR PROCEDURE A: DPF DeSoot. b. If NO >> then STOP. Additional diagnosis or repair for the DPF is not needed. An inactive DTC P1451 without other symptoms does not require any repair. Confirm that the PCM has the latest updates per the relevant TSB's and include the documentation kit p/n 6804917AA (while supplies last) in the vehicle, and resolve any other concerns prior to returning the vehicle to the owner. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURES: NOTE: Detailed removal and installation procedures (and graphics), required to perform this bulletin, will not be listed individually in each Inspection and Test Section of this Repair Procedure. It will be important to refer to TechCONNECT for all detailed service procedures. REPAIR PROCEDURE A: DPF DeSoot 1. Resolve all DTC's unrelated to DeSoot. NOTE: DeSoot only addresses the amount of particulate matter (soot) in the DPF, such as indicated by an active P1451. It DOES NOT address any other issues or conditions. 2. Confirm the PCM Calibration software is at the latest revision level. If an update is required, follow the latest calibration update TSB. WARNING: Elevated exhaust temperatures during Scan Tool initiated DeSoot can cause personal injury or property damage. It is important that ALL procedures are followed. 3. Refer to TSB or Service Information available in DealerCONNECT for information to perform a Scan Tool initiated DeSoot. REPAIR PROCEDURE B: DPF Repair Procedure NOTE: The DPF repair procedure has been updated due to diagnostic and controls enhancements. 1. Does the vehicle have a no start condition WITHOUT P242F in the PCM? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Diesel Particle Filter (DPF): > 11-001-09 > Jul > 09 > Engine Controls - MIL ON/DTC's P1451/P200C/P242F > Page 5961 a. If YES »> then proceed to Step # 2. b. If NO »> then proceed to Step # 3. 2. Disconnect the DPF from the NOx Absorber Catalyst (NAG) by removing the three nuts at the flange between them. Insert a non-flammable spacer between the NAG and DPF flanges to create an exhaust leak path. Does this resolve the no start condition? a. Yes >> proceed to Step # 3. b. No >> then STOP. The no start condition is NOT caused by the DPF. DPF replacement is NOT needed, and this bulletin DOES NOT apply. 3. Replace the DPF. Refer to the detailed removal and installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 11 - Exhaust Systems > Converter, Catalytic > Removal/Installation > 6.7L diesel P/U. 4. Clean the EGR valve. Refer to the detailed cleaning procedures available in DealerCONNECT > TechCONNECT under: 25 - Emissions Controls > Exhaust Gas Recirculation, 6.7L Diesel > Valve, Exhaust Gas Recirculation (EGR), 6.7L > Cleaning. 5. Ensure all other engine driveability symptom and/or aftertreatment-related DTC's are addressed. 6. Confirm the PCM application software is at the latest revision level. If an update is required, follow the latest calibration update TSB. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Use Standard Labor Operation Times FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description Diesel Particle Filter (DPF): Description and Operation Description DESCRIPTION DIESEL OXIDATION CATALYST (DOC) The Diesel Oxidation Catalyst (DOC) is a ceramic flow through substrate coated with a catalyst washcoat that is integral to the DOC assembly. The close coupled DOC treats engine exhaust gases by converting harmful carbon monoxide, unburned hydrocarbons and other compounds into water, carbon dioxide and heat. Pick-up vehicles use a separate DOC assembly. Cab-Chassis vehicles use a combination Diesel Oxidation Catalyst/Diesel Particulate Filter (DOC/DPF) DIESEL PARTICULATE FILTER The Diesel Particulate Filter (DPF) is a wall-pass ceramic filter substrate coated with a catalyst washcoat that is integral to the DOC/DPF assembly. The partially treated exhaust gases from the DOC, flow into the catalyzed diesel particulate filter (DPF) which traps and accumulates particulate matter and further treats the exhaust gases to reduce unburned hydrocarbons and other harmful compounds. the trapped particulate molecules will be periodically removed from the DPF via a thermal regeneration process initiated by the engine's electronic control module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Description > Page 5964 Diesel Particle Filter (DPF): Description and Operation Operation OPERATION The oxidation catalyst raises the exhaust gas temperatures to regenerate the DPF, which is passive regeneration. If the passive regeneration cannot keep up with the build up of soot in the DPF, the ECM will actively regenerate the DPF to burn off the soot. Residue remains inside the DPF in the form of non burnable ash. Ash comes from the oils and other materials that are trapped in the oils and are present in the soot. The catalyst contains a large number of parallel channels, which run in the axial direction and are separated by thin porous walls. The channels are alternatively open at one end, but plugged at the other. The exhaust gases flow through the walls and escape through the pores in the wall material. Particulates, however, are too large to escape and are trapped in the monolith walls. The ECM starts the regeneration of the DPF if the soot load exceeds a performance map value. The ECM determines the load condition of the DPF based upon the exhaust gas pressure upstream and downstream of the DPC/DPF. A pressure differential sensor provides the pressure input to the ECM. During the regeneration process, the ECM raises the temperature in the DOC/DPF to burn off the soot accumulated. Under normal operation, the engine does not produce enough heat to oxidize the soot inside the DOC/DPF. This process requires temperatures above 550°C (1,022°F). After regeneration, the ECM reads the actual pressure difference at the DOC/DPF and compares it with a reference value. From this comparison, the ECM determines the ash quantity inside the DOC/DPF. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Description and Operation > Page 5965 Diesel Particle Filter (DPF): Testing and Inspection DIESEL PARTICULATE FILTER EVIC Message Center - Message - Catalyst Full The engine Electronic Control Module (ECM) monitors the soot load in the diesel particulate filter. Under normal operating conditions the diesel particulate filter is self-cleaning, where accumulated soot is converted to ash. Under light load operating conditions, the driver may be notified via the vehicle's Electronic Vehicle Information Center (EVIC) message center "CATALYST FULL: SEE OWNERS MAN" message will be displayed indicating that it is necessary to modify the vehicles driving routine/duty-cycle in order to allow the diesel particulate filter system to self clean. If the vehicle's EVIC message center notification is ignored, the vehicle will eventually derate the engine and set a fault, requiring service. The soot load in the diesel particulate filter is estimated by the ECM using the Exhaust Pressure Sensor values and the calculated soot output of the engine. This fault code will be triggered if the application is not operating at a duty cycle high enough to allow active regeneration of the diesel particulate filter. This fault code is an indication that the exhaust temperatures exiting the turbocharger are not high enough to allow active regeneration of the soot that is trapped in the diesel particulate filter. It may be necessary to increase the duty cycle of the application in order to prevent excessive soot accumulation and plugging of the diesel particulate filter. The ECM will set this fault if it detects that the soot level has exceeded the normal desoot trigger threshold by a sufficient amount to indicate that the driver intervention is required. There is not a MIL lamp associated with this fault code, though the driver will be notified via the EVIC message. Have owner drive vehicle at highway speeds (50/60 mph) for a minimum of 45 minutes. If the message CATALYST FULL SERVICE REQ'D. is still displayed, Refer to appropriate testing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis Diesel Particle Filter (DPF): Service and Repair Removal - Cab Chassis 6.7L DIESEL - CAB CHASSIS WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove flexible tubing from particulate filter pressure sensor tubing. 4. Loosen and remove particulate filter pressure sensor tubing from Diesel Oxidation Catalytic/Diesel Particulate Filter (DOC/DPF). 5. Disconnect and remove temperature sensors. 6. 4X4 Vehicles Remove transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Removal . 7. 4X4 Vehicles - Remove transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal . 8. Remove exhaust pipe to DOC/DPF flange nuts (5) 9. Remove intermediate pipe to DOC/PDF clamp nuts (2). 10. Move muffler and tail pipe assembly (1) toward rear of vehicle. 11. Remove DOC/DPF (4). 12. Remove and discard flange gaskets. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 5968 Diesel Particle Filter (DPF): Service and Repair Removal - P/U REMOVAL CATALYTIC CONVERTER 6.7L - DIESEL - P/U 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect flexible exhaust differential pressure sensor tubing (2). 4. Remove exhaust pressure differential sensor tubing from Diesel Particulate Filter (DPF) (1). 5. 4X4 Vehicles - Remove transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Removal . 6. 4X4 Vehicles - Remove transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal . 7. Remove Diesel Particulate Filter (DPF) to NOx Absorber Catalyst (NAC) flange nuts (7). 8. Remove NAC to Diesel Oxidation Catalyst (DOC) to NAC flange nuts (5). Discard gasket. 9. Remove NAC (7) from isolators. 10. Remove DOC to muffler band clamp. 11. Remove DOC from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 5969 Diesel Particle Filter (DPF): Service and Repair Installation - Cab Chassis 6.7L DIESEL - CAB CHASSIS 1. Position new exhaust flange gaskets on exhaust pipe (6) to DOC/DPF flange and DOC/DPF into intermediate pipe (1). 2. Using new gasket, position the DOC/DPF (4) onto the front exhaust pipe flange. 3. Install flange nuts (5). Hand tighten only. 4. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Tighten flange nuts (5) to 54 Nm (40 ft. lbs) 6. Tighten band clamp nuts to 52 Nm (40 ft. lbs.) 7. Install temperature sensor. Tighten to 29.8 Nm (22 ft. lbs.) 8. Install exhaust differential pressure tubing. Tighten to 30 Nm (22 ft. lbs.) NOTE: Make sure there is not a dip in the pressure differential tubing. 9. Install flexible exhaust differential pressure sensor tubing. 10. 4X4 Vehicles - Install transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation . 11. 4X4 Vehicles Install transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Installation . 12. Connect electrical connectors. 13. Connect negative battery cable. 14. Using scan tool, under ENGINE MISC. FUNCTIONS, perform DIESEL PARTICULATE FILTER REPLACEMENT function. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Removal - Cab Chassis > Page 5970 Diesel Particle Filter (DPF): Service and Repair Installation - P/U 6.7L DIESEL - P/U CATALYTIC CONVERTER 6.7L - DIESEL - P/U 1. Position DOC onto muffler. Install band clamp and tighten to 54 Nm (40 ft. lbs.). 2. Using new gaskets position NAC (6) onto the DOC (4) and Diesel Particulate Filter (DPF). 3. Install DOC to NAC flange nuts. Tighten nuts to 54 Nm (40 ft. lbs.). 4. Install differential pressure tube support into DPF. Tighten tubing nuts to Tighten fittings to 30 Nm (22 ft. lbs.). NOTE: Make sure there is not a dip in the pressure differential hoses. 5. Install flexible differential pressure tubing (2). 6. 4X4 Vehicles - Install transmission crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation . 7. 4X4 Vehicles - Install transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Transfer Case Skid Plate/Installation . 8. Check the exhaust system for contact with the body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 9. Lower the vehicle. 10. Connect negative battery cable (s). 11. Using scan tool, under ENGINE MISC. FUNCTIONS, perform DIESEL PARTICULATE FILTER REPLACEMENT function. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Component ID: 456 Component : SOLENOID-EVAP PURGE Connector: Name : SOLENOID-EVAP PURGE Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K52 20DB/WT EVAP PURGE CONTROL 2 K70 20DB/BR EVAP PURGE SOL SIGNAL Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 5975 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 5976 Canister Purge Solenoid: Diagrams Component ID: 456 Component : SOLENOID-EVAP PURGE Connector: Name : SOLENOID-EVAP PURGE Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K52 20DB/WT EVAP PURGE CONTROL 2 K70 20DB/BR EVAP PURGE SOL SIGNAL Component Location - 32 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 5977 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Removal Canister Purge Solenoid: Service and Repair Removal REMOVAL The duty cycle EVAP canister purge solenoid (1) is located in the engine compartment below and near the battery. 1. Carefully pull the solenoid assembly straight up from the tongue-type bracket without bending the two vapor lines. 2. Disconnect electrical wiring connector (2) at solenoid. 3. Disconnect vapor line quick-connect fitting (3) at solenoid. 4. Disconnect vapor line quick-connect fitting (4) at solenoid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Removal > Page 5980 Canister Purge Solenoid: Service and Repair Installation INSTALLATION 1. Connect vapor line quick-connect fitting (3) to solenoid. 2. Connect vapor line quick-connect fitting (4) to solenoid. 3. Connect electrical wiring connector (2) to solenoid. 4. Carefully push the solenoid assembly (1) straight down onto the tongue-type bracket without bending the two vapor lines. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Evaporative Emissions Canisters Type-1 Canisters A single, vertically mounted EVAP canister (1) is used with Type 1. The ESIM (Emission System Integrity Monitor) switch (3) is mounted to the canister. Type-2 Canisters A single, vertically mounted EVAP canister (1) is used with Type 2. The ESIM (Emission System Integrity Monitor) switch (2) is mounted to the canister. Type-3 Canisters Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 5984 Dual, vertically mounted EVAP canisters (1) and (4) are used with Type 3. The ESIM (Emission System Integrity Monitor) switch (2) is mounted to the main canister (1). Canister (4) is considered a secondary canister. Type-4 Canisters Dual, horizontally mounted EVAP canisters (1) and (7) are used with Type 4. The ESIM (Emission System Integrity Monitor) switch (3) is mounted to the main, primary canister (1). Canister (7) is considered a secondary canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 5985 Evaporative Emission Control Canister: Description and Operation OPERATION Depending on engine displacement, either one or two EVAP canisters may be used. Also depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. The ESIM (Emission System Integrity Monitor) switch is mounted to the EVAP canister. The NVLD system is no longer used on any engine. The EVAP canister(s) are filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canisters are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canisters. Fuel vapors are temporarily held in the canisters until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canisters to be purged at predetermined times and at certain engine operating conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal Evaporative Emission Control Canister: Service and Repair Removal REMOVAL Type-1 Canisters A single, vertically mounted EVAP canister (1) is used with Type 1. The ESIM (Emission System Integrity Monitor) switch (3) is mounted to the canister. 1. Raise and support vehicle. 2. If equipped, remove necessary skid plates. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). 3. Disconnect electrical wiring connector from ESIM switch (3). 4. Disconnect vapor line (6) from ESIM switch. 5. Disconnect quick-connect vapor line (5) from canister. 6. Remove canister mounting bracket bolt. This is located below and near the ESIM switch. 7. Pull canister from mounting bracket while guiding two canister locating pins from mounting bracket. Type-2 Canisters A single, vertically mounted EVAP canister (1) is used with Type 2. The ESIM (Emission System Integrity Monitor) switch (2) is mounted to the canister. 1. Raise and support vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 5988 2. If equipped, remove necessary skid plates. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). 3. Disconnect electrical wiring connector from ESIM switch (3). 4. Disconnect vapor line (7) from ESIM switch. 5. Disconnect quick-connect vapor line (5) at canister. 6. Remove canister mounting bracket bolt (6). 7. Pull canister from mounting bracket while guiding two canister locating pins from mounting bracket. Type-3 Canisters Dual, vertically mounted EVAP canisters (1) and (4) are used with Type 3. The ESIM (Emission System Integrity Monitor) switch (2) is mounted to the main canister (1). Canister (4) is considered a secondary canister. 1. Raise and support vehicle. 2. If equipped, remove necessary skid plates. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). 3. Disconnect electrical wiring connector from ESIM switch (3). 4. Disconnect vapor line (9) from ESIM switch. 5. Disconnect quick-connect vapor line (7) at main canister. 6. Remove canister mounting bracket bolt (8). 7. Pull canister from mounting bracket while guiding two canister locating pins from mounting bracket. 8. To remove the secondary canister (4), remove mounting bolt. Pull canister from mounting bracket while guiding two canister locating pins (6) from mounting bracket. Type-4 Canisters Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 5989 Dual, horizontally mounted EVAP canisters (1) and (7) are used with Type 4. The ESIM (Emission System Integrity Monitor) switch (3) is mounted to the main, primary canister (1). Canister (7) is considered a secondary canister. 1. Raise and support vehicle. 2. If equipped, remove necessary skid plates. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). 3. Disconnect electrical wiring connector from ESIM switch (4). 4. Disconnect vapor line (5) from ESIM switch. 5. Disconnect quick-connect vapor line (8) at main canister. 6. Remove primary canister mounting bracket nut (9). 7. Pull canister from mounting bracket while guiding two canister locating pins from mounting bracket. 8. To remove the secondary canister (7), remove mounting nut (6). Pull canister from mounting bracket while guiding two canister locating pins from mounting bracket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 5990 Evaporative Emission Control Canister: Service and Repair Installation INSTALLATION Type-1 Canisters CAUTION: After installing any EVAP canister or ESIM switch, the electrical connector on the switch MUST be in the 3 O'clock position (as viewed from front). This step must be done for proper ESIM switch operation. A single, vertically mounted EVAP canister (1) is used with Type 1. The ESIM (Emission System Integrity Monitor) switch (3) is mounted to the canister. 1. Two locating pins are located at rear of canister. Push these two pins into canister mounting bracket. 2. Install canister mounting bracket bolt. This is located below and near the ESIM switch. 3. Connect quick-connect vapor line (5) to canister. 4. Connect vapor line (6) to ESIM switch. 5. Connect electrical wiring connector to ESIM switch (3). 6. If equipped, install necessary skid plates. 7. All vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 8. Lower vehicle. Type-2 Canisters CAUTION: After installing any EVAP canister or ESIM switch, the electrical connector on the switch MUST be in the 3 O'clock position (as viewed from front). This step must be done for proper ESIM switch operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 5991 A single, vertically mounted EVAP canister (1) is used with Type 2. The ESIM (Emission System Integrity Monitor) switch (2) is mounted to the canister. 1. Two locating pins are located at rear of canister. Push these two pins into canister mounting bracket. 2. Install canister mounting bracket bolt (6). 3. Connect quick-connect vapor line (5) to canister. 4. Connect vapor line (7) to ESIM switch. 5. Connect electrical wiring connector to ESIM switch (3). 6. If equipped, install necessary skid plates. 7. All vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 8. Lower vehicle. Type-3 Canisters CAUTION: After installing any EVAP canister or ESIM switch, the electrical connector on the switch MUST be in the 3 O'clock position (as viewed from front). This step must be done for proper ESIM switch operation. Dual, vertically mounted EVAP canisters (1) and (4) are used with Type 3. The ESIM (Emission System Integrity Monitor) switch (2) is mounted to the main canister (1). Canister (4) is considered a secondary canister. 1. Push secondary canister (4) into mounting bracket while guiding two canister locating pins (6) into mounting bracket. Install mounting bolt. 2. Push main, primary canister (1) into mounting bracket while guiding two canister locating pins into mounting bracket. 3. Install main canister mounting bracket bolt (8). 4. Connect quick-connect vapor line (7) to main canister. 5. Connect vapor line (9) to ESIM switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 5992 6. Connect electrical wiring connector to ESIM switch (3). 7. If equipped, install necessary skid plates. 8. All vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 9. Lower vehicle. Type-4 Canisters CAUTION: After installing any EVAP canister or ESIM switch, the electrical connector on the switch MUST be in the 3 O'clock position (as viewed from front). This step must be done for proper ESIM switch operation. Dual, horizontally mounted EVAP canisters (1) and (7) are used with Type 4. The ESIM (Emission System Integrity Monitor) switch (3) is mounted to the main, primary canister (1). Canister (7) is considered a secondary canister. 1. Position two secondary canister locating pins into mounting bracket. Install mounting nut (6). 2. Position two primary canister locating pins into mounting bracket. 3. Install primary canister mounting bracket nut (9). 4. Connect quick-connect vapor line (8) to main canister. 5. Connect vapor line (5) to ESIM switch. 6. Connect electrical wiring connector to ESIM switch (4). 7. If equipped, install necessary skid plates. 8. All vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 9. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Description and Operation Evaporative Emissions Hose: Description and Operation DESCRIPTION A vacuum schematic for emission related items can be found on the vehicles VECI label. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Component ID 474 Leak Detector: Locations Component ID 474 Component ID: 474 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 Z910 20BK GROUND 2 K107 20VT/WT ESM SIGNAL Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Component ID 474 > Page 6000 Component Location - 69 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Component ID 474 > Page 6001 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Component ID 474 > Page 6002 Leak Detector: Locations Component ID 487 Component ID: 487 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 Z910 20BK GROUND 2 K107 20VT/WT ESM SIGNAL Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Component ID 474 > Page 6003 Component Location - 69 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Component ID 474 > Page 6004 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Diagrams > Component ID 474 Leak Detector: Diagrams Component ID 474 Component ID: 474 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 Z910 20BK GROUND 2 K107 20VT/WT ESM SIGNAL Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Diagrams > Component ID 474 > Page 6007 Component Location - 69 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Diagrams > Component ID 474 > Page 6008 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Diagrams > Component ID 474 > Page 6009 Leak Detector: Diagrams Component ID 487 Component ID: 487 Component : SWITCH-EVAP SYSTEM MONITOR Connector: Name : SWITCH-EVAP SYSTEM MONITOR Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 Z910 20BK GROUND 2 K107 20VT/WT ESM SIGNAL Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Diagrams > Component ID 474 > Page 6010 Component Location - 69 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Diagrams > Component ID 474 > Page 6011 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Description Refueling Vapor Recovery System: Description and Operation Description DESCRIPTION The ORVR (On-Board Refueling Vapor Recovery) system consists of a unique fuel tank, flow management valve, fluid control valve, one-way check valve and vapor canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Description > Page 6016 Refueling Vapor Recovery System: Description and Operation Operation OPERATION The ORVR (On-Board Refueling Vapor Recovery) system is used to remove excess fuel tank vapors. This is done while the vehicle is being refueled. Fuel flowing into the fuel filler tube (approx. 1" I.D.) creates an aspiration effect drawing air into the fuel fill tube. During refueling, the fuel tank is vented to the EVAP canister to capture escaping vapors. With air flowing into the filler tube, there are no fuel vapors escaping to the atmosphere. Once the refueling vapors are captured by the EVAP canister, the vehicle's computer controlled purge system draws vapor out of the canister for the engine to burn. The vapor flow is metered by the purge solenoid so that there is no, or minimal impact on driveability or tailpipe emissions. As fuel starts to flow through the fuel fill tube, it opens the normally closed check valve and enters the fuel tank. Vapor or air is expelled from the tank through the control valve and on to the vapor canister. Vapor is absorbed in the EVAP canister until vapor flow in the lines stops. This stoppage occurs following fuel shut-off, or by having the fuel level in the tank rise high enough to close the control valve. This control valve contains a float that rises to seal the large diameter vent path to the EVAP canister. At this point in the refueling process, fuel tank pressure increases, the check valve closes (preventing liquid fuel from spiting back at the operator), and fuel then rises up the fuel filler tube to shut off the dispensing nozzle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Recalls for EGR Cooler: > NHTSA08V641000 > Dec > 08 > Recall 08V641000: Potential Engine Compartment Fire EGR Cooler: Recalls Recall 08V641000: Potential Engine Compartment Fire VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/RAM 2500 2007-2008 Dodge/RAM 3500 2007-2008 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: December 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V641000 NHTSA ACTION NUMBER: N/A COMPONENT: Engine and Engine Cooling: Engine: Diesel POTENTIAL NUMBER OF UNITS AFFECTED: 108429 SUMMARY: Chrysler is recalling 108,429 M/Y 2007-2008 Dodge RAM 2500 and 3500 pickup trucks equipped with 6.7L Diesel engines. A silencer pad can sag and contact the Exhaust Gas Recirculation (EGR) cooler. CONSEQUENCE: This could result in an engine compartment fire. REMEDY: Dealers will add a bracket to support the engine compartment silencer pad adjacent to the EGR cooler. The recall is expected to begin during December 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H34. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for EGR Cooler: > NHTSA08V641000 > Dec > 08 > Recall 08V641000: Potential Engine Compartment Fire EGR Cooler: All Technical Service Bulletins Recall 08V641000: Potential Engine Compartment Fire VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/RAM 2500 2007-2008 Dodge/RAM 3500 2007-2008 MANUFACTURER: Chrysler LLC. MFR'S REPORT DATE: December 04, 2008 NHTSA CAMPAIGN ID NUMBER: 08V641000 NHTSA ACTION NUMBER: N/A COMPONENT: Engine and Engine Cooling: Engine: Diesel POTENTIAL NUMBER OF UNITS AFFECTED: 108429 SUMMARY: Chrysler is recalling 108,429 M/Y 2007-2008 Dodge RAM 2500 and 3500 pickup trucks equipped with 6.7L Diesel engines. A silencer pad can sag and contact the Exhaust Gas Recirculation (EGR) cooler. CONSEQUENCE: This could result in an engine compartment fire. REMEDY: Dealers will add a bracket to support the engine compartment silencer pad adjacent to the EGR cooler. The recall is expected to begin during December 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H34. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Page 6031 EGR Cooler: Locations Location The Exhaust Gas Recycling cooler is located above the exhaust manifold on the right side of the engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Page 6032 EGR Cooler: Diagrams Component ID: 530 Component : VALVE-EGR COOLER BYPASS Connector: Name : VALVE-EGR COOLER BYPASS Color : # of pins : 4 Qualifier : (6.7L DH/D1) Pin Circuit Description 1 K671 18BR/DB EGR BYPASS STATUS 2 K670 18BR/LB EGR BYPASS VALVE SIGNAL 3 F348 16PK/OR SMART POWER RELAY FEED 4 K972 18DB/TN ACTUATOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Description and Operation > Description EGR Cooler: Description and Operation Description DESCRIPTION The Exhaust Gas Recycling cooler is located above the exhaust manifold on the right side of the engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Description and Operation > Description > Page 6035 EGR Cooler: Description and Operation Operation OPERATION Exhaust gas enter the rear portion of the EGR Cooler from the exhaust manifold. The gas is cooled as it passes through the EGR Cooler and then enters the EGR crossover tube and is routed to the EGR valve. Coolant enters the rear of the EGR Cooler and flow the same direction as the exhaust gases. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures EGR Cooler: Procedures CLEANING 1. Remove EGR Cooler See: Removal and Replacement/EGR Cooler - Removal . 2. Spray the internal cavity of EGR Cooler with hot tap water for 10 minutes. 3. Plug EGR Cooler outlet (1) with a locally obtained rubber expansion plug to make a watertight seal. 4. Following instruction on the container, mix MOPAR(R) EGR System Cleaner and hot tap water with a ratio of one part EGR Cleaner, four parts water. 5. Position EGR Cooler with the outlet (1) facing up. Fill EGR Cooler with hot tap water and MOPAR(R) EGR System Cleaner until cooler is completely full. Soak for one hour. 6. Remove plug from EGR Cooler outlet (1). Drain cleaning solution from cooler. Discard according to local governmental regulations. 7. Rinse cooler using hot tap water until all cleaning solution has been rinsed clean. Dry completely. 8. Install EGR Cooler See: Removal and Replacement/EGR Cooler - Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6038 EGR Cooler: Removal and Replacement P/U P/U WARNING: Locking constant tension hose clamps are used on the EGR cooler system hoses. When removing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing locking constant tension clamps. 1. Remove engine cover (1). 2. Drain cooling system below level of EGR cooler See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 3. Disconnect EGR bypass control electrical connector (1). 4. Remove EGR bypass control assembly mounting bolts (2) and position aside. 5. Remove air transfer tube assembly heat shield. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6039 6. Loosen EGR valve mounting bolts. Do not remove bolts. 7. Remove EGR crossover tube to EGR cooler and EGR valve clamps (1 and 3). 8. Remove EGR crossover tube clamp (5). 9. Remove EGR crossover tube (2). 10. Remove clamp at front of EGR cooler. 11. Remove Air Transfer Tube assembly. 12. If damaged, separate Air Transfer Tube from Brace assembly. Discard gasket. EGR COOLER - 6.7L DIESEL - CAB-CHASSIS 13. Using Tool 6094, remove forward coolant tube (6) from EGR cooler (2). 14. Using Tool 6094, remove breather tube (7). 15. Using Tool 6094, remove rear coolant tube (8) from EGR cooler (2). 16. Remove EGR Transfer Connection Tube from casting. 17. Remove EGR cooler flange nuts (1). 18. Remove EGR cooler mount bolts. 19. Remove EGR cooler. Discard flange gasket. 20. If damaged, remove EGR cooler mounting support. Cab Chassis CAB CHASSIS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6040 WARNING: Locking constant tension hose clamps are used on the EGR cooler system hoses. When removing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing locking constant tension clamps. 1. Remove engine cover (1). 2. Drain cooling system below level of EGR cooler See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 3. Remove EGR heat shield. 4. Disconnect EGR temperature sensor electrical connector (4). 5. Loosen EGR valve mounting bolts. Do not remove. 6. Remove EGR crossover tube clamp (5). 7. Remove EGR crossover tube clamp (3). 8. Remove EGR crossover tube clamp (1 and 3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6041 EGR COOLER - 6.7L DIESEL - CAB-CHASSIS 9. Using Tool 6094, remove forward coolant tube (6) from EGR cooler (2). 10. Using Tool 6094, remove breather tube (7). 11. Using Tool 6094, remove rear coolant tube (8) from EGR cooler (2). 12. Remove EGR Transfer Connection Tube from casting, (if equipped). 13. Remove EGR cooler flange nuts (1). 14. Remove EGR cooler mount bolts. 15. Remove EGR cooler. Discard flange gasket. 16. If damaged, remove EGR Cooler support bracket. P/U P/U EGR COOLER - 6.7L DIESEL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6042 WARNING: Locking constant tension hose clamps are used on the EGR cooler system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing locking constant tension clamps. 1. Install EGR cooler support bracket, if removed. Tighten mounting bolts to 32 Nm (24 ft. lbs.). 2. Using a new gasket, position EGR cooler (2) on exhaust manifold flange. Tighten flange nuts to 43 Nm (32 ft. lbs). 3. Install EGR Cooler mounting bolts. Using a criss-cross pattern, tighten bolts to 24 Nm (18 ft. lbs.). 4. If separated, using a new gasket, assemble brace and Air Transfer tube. Tighten bolts to 24 Nm (18 ft.lbs). 5. Using a new gasket, install Air Transfer Tube assembly on exhaust manifold. Tighten nuts to 43 Nm (32 ft.lbs). 6. Install clamp at EGR Cooler. Tighten clamp to 10 Nm (89 in. lbs.). 7. Using new gasket (5), position EGR crossover tube (4) to EGR Cooler. Install clamp (6) finger tight. 8. Using new gasket (2), position EGR crossover tube (4) to EGR Valve. Install clamp (1) finger tight. 9. Tighten clamps (1 and 6) to 10 Nm (89 in. lbs.). 10. Install brace bolt (3). Tighten bolt (3) to 24 Nm (18 ft. lbs.). 11. Tighten EGR Valve mounting bolts to 24 Nm (18 ft. lbs.) 12. Install EGR Valve heat shield. Tighten mounting nut to 10 Nm (89 in. lbs.). 13. Install Air Transfer Tube heat shield. Tighten bolt to 10 Nm (89 in. lbs.). 14. Install EGR Control Assembly so that wire cable restraint is tight. Tighten mounting bolts to 24 Nm (18 ft. lbs.). 15. Install EGR Control Assembly electrical connector (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6043 CAUTION: Locking constant tension clamps will SNAP when released. NOTE: Locking constant tension clamps can be released using a suitable screwdriver. 16. Position locking constant tension clamp (1) on froward coolant tube (4) and install tube. 17. Using a suitable screwdriver (3), release constant tension clamp (1). 18. Position locking constant tension clamp on rear coolant tube and install tube. 19. Using a suitable screwdriver, release constant tension clamp 20. Position locking constant tension clamp on breather tube and install tube. 21. Using a suitable screwdriver, release constant tension clamp. 22. Fill coolant system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 23. Install engine cover. 24. Connect negative battery cable(s). 25. Start engine and check for coolant or exhaust leaks. Cab Chassis INSTALLATION - CAB CHASSIS EGR COOLER - 6.7L DIESEL - CAB-CHASSIS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6044 WARNING: Locking constant tension hose clamps are used on the EGR cooler system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing locking constant tension clamps. 1. Install EGR cooler support bracket, if removed. Tighten mounting bolts to 32 Nm (24 ft. lbs.). 2. Using a new gasket, position EGR cooler (2) on exhaust manifold flange. Tighten flange nuts to 43 Nm (32 ft. lbs). 3. Install EGR Cooler mounting bolts. Using a criss-cross pattern, tighten bolts to 24 Nm (18 ft. lbs.). CAUTION: Locking constant tension clamps will SNAP when released. NOTE: Locking constant tension clamps can be released using a suitable screwdriver. 4. Position locking constant tension clamp (1) on froward coolant tube (4) and install tube. 5. Using a suitable screwdriver (3), release constant tension clamp (1). 6. Position locking constant tension clamp on rear coolant tube and install tube. 7. Using a suitable screwdriver, release constant tension clamp 8. Position locking constant tension clamp on breather tube and install tube. 9. Using a suitable screwdriver, release constant tension clamp. 10. Using new gasket, position EGR crossover tube (2) to EGR Cooler. Install clamp (1) finger tight. 11. Using new gasket, position EGR crossover tube (2) to EGR Valve (3). Install clamp (1) finger tight. 12. Tighten clamps (1 and 3) to 10 Nm (89 in. lbs.). 13. Install clamp (5). Tighten clamp to 10 Nm (89 in. lbs.). 14. Tighten EGR Valve mounting bolts to 24 Nm (18 ft. lbs.) 15. Install EGR Valve heat shield. Tighten mounting nut to 10 Nm (89 in. lbs.). 16. Connect EGR valve electrical connector (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6045 17. Install engine cover (1). 18. Connect negative battery cable. 19. Fill cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Cooler Bypass Valve Assembly (1) is mounted between the EGR crossover tube and the EGR cooler. Two mechanical cables (3) join the units together. An electrical drive servo (4) moves the cables (3) to operate a butterfly plate (2) within a cast manifold. Parts 1, 2, 3 and 4 are serviced as one entire assembly. Do not attempt to disassemble unit. 1. Disconnect and isolate both negative battery cables at both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6046 2. Remove four bolts (2) and remove EGR tube cover (1). 3. Loosen and remove two clamps (1) and (6) at ends of EGR Crossover Tube. 4. Remove clamp mounting bolt (3) at center of EGR Crossover Tube. 5. Remove EGR Crossover Tube (4). 6. Remove and discard gaskets (doughnuts) at each end of tube (2) and (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6047 7. Remove nuts (7) and remove upper heat shield (6). 8. Remove bolts (10), nut (8) and remove lower heat shield (9). 9. Remove bolts (5) and (14). 10. Separate casting (4) from casting (15) and discard gasket (3). 11. Disconnect electrical connector (1). 12. Remove bracket bolts (2) at outside of mounting bracket. 13. Remove bracket bolts at inside of mounting bracket. 14. Remove EGR cooler bypass valve assembly from engine. Installation-Pick Up Models INSTALLATION-PICK UP MODELS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6048 1. Clean gasket mating surfaces on castings (4) and (15). 2. Position EGR cooler bypass valve assembly to engine. 3. Position new gasket (3) between castings (4) and (15). 4. Install bolts (5) and (14). Do not tighten these bolts at this time. 5. Install bracket bolts (2) at outside of mounting bracket. Do not tighten these bolts at this time. 6. Install bracket bolts at inside of mounting bracket. Do not tighten these bolts at this time. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6049 7. Tighten bolts (5) and (14) to 24 Nm (18 ft. lbs.) torque. 8. Tighten bracket bolts (2) at outside of mounting bracket to 24 Nm (18 ft. lbs.) torque. 9. Tighten bracket bolts at inside of mounting bracket to 24 Nm (18 ft. lbs.) torque. 10. Connect electrical connector (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6050 11. Clean each end of EGR crossover tube and its connection points of any old gasket material 12. Install new gaskets (doughnuts) (2) and (5) to each end of tube. 13. Position EGR crossover tube (4) to engine. 14. Position bolt (3) at center of EGR crossover tube. Install bolt loosely (finger tight). 15. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (6) to 10 Nm (7 ft. lbs.). 16. Tighten clamp bolt (3) to 10 Nm (7 ft. lbs.). 17. Install upper heat shield (6) and nuts (7). Tighten nuts to 24 Nm (18 ft. lbs.) torque. 18. Install lower heat shield (9), bolts (10), and nut (8). Tighten nut/bolts to 24 Nm (18 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Procedures > Page 6051 19. Install EGR tube cover (1) and four bolts (2). 20. Connect and both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 409 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K935 18DB EGR TEMPERATURE SENSOR SIGNAL Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K935 18DB EGR TEMPERATURE SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 6057 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6060 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. 4. Unscrew nut (2) at intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6061 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6062 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6063 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6064 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal EGR Tube: Service and Repair Removal Removal-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS 1. Clean each end of EGR crossover tube, and its connection points of any old gasket material 2. Install new gaskets (doughnuts) to each end of tube. 3. Position EGR crossover tube (2) to engine. 4. Position "P" clamp (5) at center of EGR crossover tube. Install "P" clamp bolt loosely (finger tight). 5. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (3) to 10 Nm (7 ft. lbs.). 6. Tighten "P" clamp bolt (5) to 10 Nm (7 ft. lbs.). 7. Connect electrical connector (4) to EGR temperature sensor. 8. Install heat shield (2) over EGR valve (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6069 9. Install cover (1) and four cover bolts (2). 10. Connect both negative battery cables to both batteries. Removal-Pick Up Models INSTALLATION-PICK UP MODELS 1. Clean each end of EGR crossover tube and its connection points of any old gasket material 2. Install new gaskets (doughnuts) (2) and (5) to each end of tube. 3. Position EGR crossover tube (4) to engine. 4. Position bolt (3) at center of EGR crossover tube. Install bolt loosely (finger tight). 5. First, tighten EGR tube clamp (1) to 10 Nm (7 ft. lbs.), then tighten clamp (6) to 10 Nm (7 ft. lbs.). 6. Tighten clamp bolt (3) to 10 Nm (7 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6070 7. Install heat shield (2) over EGR valve (1). 8. Install cover (1) and four cover bolts (2). 9. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6071 EGR Tube: Service and Repair Installation Installation-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS 1. Disconnect and isolate both negative battery cables at batteries. 2. Remove four bolts (2) and EGR crossover tube cover (1). 3. Remove heat shield (2) over EGR valve (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6072 4. Disconnect electrical connector (4) at EGR Temperature Sensor. 5. Loosen and remove two clamps (1) and (3) at ends of EGR Crossover Tube. 6. Remove "P" clamp mounting bolt (5) at center of EGR Crossover Tube. 7. Remove EGR Crossover Tube (2). 8. Remove and discard gaskets (doughnuts) at each end of tube. Installation-Pick Up Models REMOVAL-PICK UP MODELS 1. Disconnect and isolate both negative battery cables at batteries. 2. Remove four bolts (2) and EGR crossover tube cover (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Removal > Page 6073 3. Remove heat shield (2) over EGR valve (1). 4. Loosen and remove two clamps (1) and (6) at ends of EGR Crossover Tube. 5. Remove clamp mounting bolt (3) at center of EGR Crossover Tube. 6. Remove EGR Crossover Tube (4). 7. Remove and discard gaskets (doughnuts) at each end of tube (2) and (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve EGR Valve: Locations Assembly-EGR Valve Component ID: 16 Component : ASSEMBLY-EGR VALVE Connector: Name : ASSEMBLY-EGR VALVE Color : # of pins : 8 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K687 18DB/LB EGR SIGNAL NO. 3 3 K685 18DB EGR SIGNAL NO. 2 4 K683 18DB/GY EGR SIGNAL NO. 1 5 K916 18BR/OR SENSOR GROUND 6 K686 18GY/DB EGR CONTROL NO. 3 7 K684 18DB/YL EGR CONTROL NO. 2 8 K682 18DB/WT EGR CONTROL NO. 1 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6078 Connector: Name : ASSEMBLY-EGR VALVE Color : PINK # of pins : 8 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K687 18DB/LB EGR SIGNAL NO. 3 3 K685 18DB EGR SIGNAL NO. 2 4 K683 18DB/GY EGR SIGNAL NO. 1 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6079 5 K916 18BR/OR SENSOR GROUND 6 K686 18GY/DB EGR CONTROL NO. 3 7 K684 18DB/YL EGR CONTROL NO. 2 8 K682 18DB/WT EGR CONTROL NO. 1 Component Location - 11 Connector: Name : ASSEMBLY-EGR VALVE Color : BLACK # of pins : 6 Qualifier : (GAS EXCEPT 5.7L HD) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6080 Pin Circuit Description 1 K34 20DB/LG EGR SIGNAL 2 F856 20YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 Z335 20BK/WT GROUND 5-6 K35 20DB/VT EGR SOL CONTROL Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6081 EGR Valve: Locations Valve-EGR Airflow Control Component ID: 529 Component : VALVE-EGR AIRFLOW CONTROL Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 2 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 3 F348 16PK/OR SMART POWER RELAY FEED 4 K971 18BR/PK SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6082 Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 2 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 3 F348 16PK/OR SMART POWER RELAY FEED 4 K971 18BR/PK SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Assembly-EGR Valve > Page 6083 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve EGR Valve: Diagrams Assembly-EGR Valve Component ID: 16 Component : ASSEMBLY-EGR VALVE Connector: Name : ASSEMBLY-EGR VALVE Color : # of pins : 8 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K687 18DB/LB EGR SIGNAL NO. 3 3 K685 18DB EGR SIGNAL NO. 2 4 K683 18DB/GY EGR SIGNAL NO. 1 5 K916 18BR/OR SENSOR GROUND 6 K686 18GY/DB EGR CONTROL NO. 3 7 K684 18DB/YL EGR CONTROL NO. 2 8 K682 18DB/WT EGR CONTROL NO. 1 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6086 Connector: Name : ASSEMBLY-EGR VALVE Color : PINK # of pins : 8 Qualifier : (6.7L) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K687 18DB/LB EGR SIGNAL NO. 3 3 K685 18DB EGR SIGNAL NO. 2 4 K683 18DB/GY EGR SIGNAL NO. 1 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6087 5 K916 18BR/OR SENSOR GROUND 6 K686 18GY/DB EGR CONTROL NO. 3 7 K684 18DB/YL EGR CONTROL NO. 2 8 K682 18DB/WT EGR CONTROL NO. 1 Component Location - 11 Connector: Name : ASSEMBLY-EGR VALVE Color : BLACK # of pins : 6 Qualifier : (GAS EXCEPT 5.7L HD) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6088 Pin Circuit Description 1 K34 20DB/LG EGR SIGNAL 2 F856 20YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 Z335 20BK/WT GROUND 5-6 K35 20DB/VT EGR SOL CONTROL Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6089 EGR Valve: Diagrams Valve-EGR Airflow Control Component ID: 529 Component : VALVE-EGR AIRFLOW CONTROL Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 2 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 3 F348 16PK/OR SMART POWER RELAY FEED 4 K971 18BR/PK SENSOR GROUND Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6090 Connector: Name : VALVE-EGR AIRFLOW CONTROL Color : # of pins : 4 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 K158 18BR/YL EGR AIRFLOW CONTROL VALVE MOTOR (+) 2 K314 18BR EGR AIRFLOW CONTROL VALVE MOTOR (-) 3 F348 16PK/OR SMART POWER RELAY FEED 4 K971 18BR/PK SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Assembly-EGR Valve > Page 6091 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal EGR Valve: Service and Repair EGR Valve - Removal REMOVAL-PICK UP MODELS 1. Use a diagnostic scan tool to record any DTC's (Diagnostic Trouble Codes). 2. Disconnect and isolate both negative battery cables at both batteries. 3. Remove four bolts (2) and remove EGR crossover tube cover (1). 4. Remove EGR valve heat shield (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6094 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6095 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6096 EGR Valve: Service and Repair EGR Valve - Cleaning CLEANING 6.7L EGR VALVE CLEANING PROCEDURE 1. Remove EGR valve assembly from engine. 2. Remove four mounting screws (4) from EGR valve motor (3). 3. Remove valve motor (6) and shim (5) from EGR valve housing (1). Motor (6) and shim (5) must be kept for reassembly. The original EGR valve motor and its shim must be reinstalled onto the original EGR valve housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6097 4. Use two fingers to press down on valve spring retainer (3) to unlock two valve keepers (2). If valve keepers will not release using finger pressure, locate a 5/8" deep socket to the spring retainer (3). Gently tap on the socket with a small hammer to release keepers, then use two fingers and press for keeper removal. 5. Remove valve spring retainer (3) and valve spring (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6098 6. Lightly press on valve stem (1) about 3/8" to force valve faces from valve seats. 7. Using a small nylon scrubbing brush, lightly brush away loose soot from EGR valve housing. 8. The EGR valve shaft stem (3) is comprised of two valve faces (1) on two valve seats. Using the same small nylon scrubbing brush, lightly brush away loose soot from stem (3), valve seat (2) and also from valve seat on EGR valve housing. 9. Completely submerge valve housing using a mixture of hot tap water and MOPAR(R) EGR System Cleaner (ESC). Mix cleaning solution 1 part Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6099 ESC and 4 parts water. Allow cleaning solution to soak for 1 hour. 10. Remove assembly from cleaning solution. Completely remove remaining soot from valve stems, both valve seats, and both valve faces using a small nylon scrubbing brush. Dispose of cleaning solution per local governmental regulations. 11. Rinse EGR valve housing in hot tap water until all cleaning solution is rinsed clean. Dry completely. 12. Assemble valve spring (2) and retainer (3) to housing. 13. Position valve keepers (2). Press down on retainer (3) until groves on valve keepers lock into valve stem (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6100 14. Install original shim (5) and original motor (6) to housing. Motor is not indexed. Rotate motor until its electrical connector is pointed towards front of vehicle. Install four mounting screws (7). 15. Install EGR valve assembly to engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6101 EGR Valve: Service and Repair EGR Valve - Installation INSTALLATION-CAB/CHASSIS MODELS 1. Install new gasket (1) to end of EGR tube. 2. Position EGR valve assembly (2) and two new gaskets to intake connection (3). 3. Install two EGR valve mounting bolts (1) and two nuts (1). Tighten four nuts/bolts finger tight only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6102 4. Install and lightly tighten two clamps (1) and (3) at ends of EGR Crossover Tube. 5. Install "P" clamp bolt (5) finger tight only. 6. Tighten clamp (1) first to 10 Nm. (7 ft. lbs.), then tighten clamp (3) to 10 Nm. (7 ft. lbs.). 7. Tighten "P" clamp bolt (5) to 10 Nm (7 ft. lbs.). 8. Tighten two EGR valve mounting bolts and two nuts (1) to 24 Nm (18 ft. lbs.). Tighten these four nuts/bolts in an alternating, criss-cross fashion. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6103 9. Connect electrical connector (5) to EGR Actuator. 10. Install EGR crossover tube cover (1) and four bolts (2). 11. Install EGR valve heat shield (2). Tighten bolts/nuts to 10 Nm (7 ft. lbs.). 12. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6104 13. Using a diagnostic scan tool, erase any previously recorded DTC's (Diagnostic Trouble Codes). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6105 EGR Valve: Service and Repair EGR Valve Air Flow Control Removal REMOVAL The EGR Air Flow Control Valve (5) is bolted to the end of the air intake connection (2). 1. Remove clamp for charge air cooler duct at point (5). Disconnect air cooler duct at this point. 2. Disconnect electrical connector at point (2). This point is located at bottom/inside of air control valve (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6106 3. Remove four mounting bolts (4) and (6) and remove air flow control valve (5). 4. Remove gasket (3) and discard. Installation INSTALLATION The EGR Air Flow Control Valve (5) is bolted to the end of the air intake connection (2). 1. Obtain new gasket (3). Before positioning new gasket (3), be sure to clean mating surfaces at top of air flow control valve and bottom of air intake connection (2). 2. Install four mounting bolts (4) and (6). Tighten four bolts to 18 Nm (13 ft. lbs.) (160 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > EGR Valve - Removal > Page 6107 3. Connect electrical connector at point (2). 4. Connect air cooler duct to bottom of air flow control valve. Install and tighten duct clamp Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 6112 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation DESCRIPTION The Closed Crankcase Ventilation System (CCV) consists of several parts to make it functional. One part is the filter. The filter is serviceable and prevents oil mist from entering the discharge tube of the CCV system. It is not cleaned, but replaced at 60,000 mile intervals. The crankcase breather assembly is integrated into the cylinder head cover (3) and is serviced separately. The external fittings (2) to the breather tube and breather drain tube are serviceable. The crankcase breather assembly is integrated into the cylinder head cover and corresponding breather cover. Crankcase gasses travel into the breather cavity under the breather cover where they pass through a filtering media (serviceable maintenance component) which separates the oil from the crankcase gasses. The oil drains back into the engine block through two hoses (2) on the left side of the engine. The crankcase gasses are directed through the Crankcase Depression Regulator (CDR) valve which allows the system to maintain a constant positive pressure in the crankcase. The CDR valve is a non-serviceable component located on the underside of the breather cover. Clean crankcase gasses flow from the CDR valve into the fresh air side of the turbocharger compressor. The closed crankcase ventilation valve is used to vent the crankcase gases back into the intake of engine. If the crankcase ventilation filter becomes too restrictive, under high intake vacuum situations, the closed crankcase ventilation prevents the engine from syphoning crankcase gases/oil from the crankcase of the engine. The closed crankcase ventilation valve is located under the crankcase ventilation filter cover at the top of the engine. TESTING 1. If troubleshooting high crankcase pressure, the following items can be causing the closed crankcase ventilation valve to close during engine Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Description and Operation > Page 6117 operation: High air intake restriction. Check for high intake restriction - A restricted crankcase ventilation filter. Change the filter - A malfunctioning or misassembled closed crankcase ventilation valve. Check the valve operation and change if necessary 2. The closed crankcase ventilation valve should allow crankcases gases to flow when the engine is not running and/or removed from the engine. NOTE: Application of air can be applied either to the inlet or outlet of the closed crankcase ventilation valve. 3. A small amount of air can be blown through the closed crankcase ventilation valve (less than 34 kPa [5 psi]) to check the closed crankcase ventilation valve. 4. If air does not go through the closed crankcase ventilation valve, replace the valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Service and Repair > Procedures Crankcase Filter: Procedures FILTER ELEMENT INSPECTION 1. Inspect the crankcase breather assembly by ensuring the oil drain hoses are not kinked or cracked. 2. Inspect all external hose connections for signs of leakage, repair where necessary. Inspect the breather for cracks or damage. 3. Inspect the filter element sealing surface for gouges or cracks; this surface should be smooth and free of abrasions. FILTER ELEMENT INSTALLATION 1. Clean the filter sealing surface on the cylinder head cover with a clean shop towel. 2. Install the new filter element, lubrication of the new sealing surface is not recommended. 3. Press the new filter into the cylinder head cover cavity until fully seated. 4. Install the breather cover assembly. BREATHER COVER INSTALLATION 1. Inspect the filter element for proper installation. The filter should be completely seated around the circumference of the sealing surface. 2. Install the breather cover to the cylinder head cover. 3. Install the capscrews surrounding the breather cover. 4. Install the breather drain hoses onto the hose barbs. Do not damage or hose connection during installation. 5. Install engine shields or covers if equipped. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Service and Repair > Procedures > Page 6120 Crankcase Filter: Removal and Replacement REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Service and Repair > Procedures > Page 6121 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6125 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6126 Crankcase Pressure Sensor: Diagrams Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Pressure Sensor > Component Information > Locations > Page 6127 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations OPERATION To comply with engine emissions regulations, a CCV (Closed Crankcase Ventilation) system has been developed for the 6.7L Cummins diesel. The CCV system reroutes crankcase ventilation (blow-by) gases from the breather assembly back into the engine intake airflow to be used for combustion. The crankcase ventilation system uses a coalescing filter (2) which captures and filters crankcase blow-by gases and then returns oil directly to the sump. The CCV system contains the following components: - Valve Cover Assembly (7) - Breather Filter (2) - Breather Filter Cover (1) - Crankcase Pressure Sensor (3) - Crankcase Differential Regulator (CDR) Valve; a part of the breather filter cover (1) The valve cover assembly (7) is made of a composite material. The cover has a recessed area for the breather filter and passages for oil draining from the breather filter, back to the crankcase. The drain tubes have one-way check valves (4), (5) and (6) that prevent oil from being forced up the tubes by excessive crankcase pressure. The Crankcase Pressure (CP) Sensor (5) is mounted on the valve cover (4). The CP sensor monitors crankcase pressure that builds up as the result of combustion gas blow-by. The Engine Control Module (ECM) uses data from the CP sensor to determine the condition of the crankcase breather (ventilation) filter. The ECM can also determine if a crankcase breather (ventilation) filter is present. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6136 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6137 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6138 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6139 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6140 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6141 Exhaust Temperature Sensor: Locations Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6142 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Locations > Sensor-Exhaust Temperature 1/1 > Page 6143 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/1 Component ID: 414 Component : SENSOR-EXHAUST TEMPERATURE 1/1 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6146 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/1 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K185 20BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Pin Circuit Description 1 K185 18BR/LB EXHAUST TEMPERATURE SENSOR 1 SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6147 2 K900 20BD/DG SENSOR GROUND 2 K900 18BD/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6148 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/2 Component ID: 415 Component : SENSOR-EXHAUST TEMPERATURE 1/2 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6149 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/2 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Pin Circuit Description 1 K186 18BR/DB EXHAUST TEMPERATURE 1/2 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6150 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6151 Exhaust Temperature Sensor: Diagrams Sensor-Exhaust Temperature 1/3 Component ID: 416 Component : SENSOR-EXHAUST TEMPERATURE 1/3 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K372 20BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6152 Connector: Name : SENSOR-EXHAUST TEMPERATURE 1/3 Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K186 20BR/DB EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Pin Circuit Description 1 K372 18BR/DG EXHAUST TEMPERATURE 1/3 SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Diagrams > Sensor-Exhaust Temperature 1/1 > Page 6153 2 K900 20DB/DG SENSOR GROUND 2 K900 18DB/DG SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description Exhaust Temperature Sensor: Description and Operation Description DESCRIPTION The Diesel Exhaust Temperature Sensors are thermistors and change resistance based on the temperature being measured. The Engine Control Module (ECM) provides a 5 volt reference voltage to the sensor. The ECM monitors the change in signal voltage and converts this to a temperature value. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Description and Operation > Description > Page 6156 Exhaust Temperature Sensor: Description and Operation Operation OPERATION When the exhaust gas temperature is cold, the sensor resistance is high, the Engine Control Module (ECM) will sense the resistance and sense the exhaust temperature as cold. When the exhaust gas temperature is high, the sensor resistance is low, the ECM will sense the resistance and sense the exhaust temperature as high. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect diesel exhaust temperature sensor electrical connector (1). 3. Remove diesel exhaust temperature sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 6159 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install the diesel exhaust temperature sensor (2). 2. Connect diesel exhaust temperature sensor electrical connector (1) 3. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations Crankcase Pressure Sensor: Locations Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6163 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6164 Crankcase Pressure Sensor: Diagrams Component ID: 406 Component : SENSOR-CRANKCASE Connector: Name : SENSOR-CRANKCASE Color : # of pins : 3 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K916 18BR/OR SENSOR GROUND 3 K926 18DB/GY CRANKCASE SENSOR SIGNAL Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Crankcase Pressure Sensor > Component Information > Locations > Page 6165 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component ID: 409 Component : SENSOR-EGR TEMPERATURE Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DC) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K935 18DB EGR TEMPERATURE SENSOR SIGNAL Connector: Name : SENSOR-EGR TEMPERATURE Color : # of pins : 2 Qualifier : (6.7L DH/D1) Pin Circuit Description 1 K914 18BR/WT SENSOR GROUND 2 K935 18DB EGR TEMPERATURE SENSOR SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models EGR Temperature Sensor: Description and Operation Operation-Cab/Chassis Models OPERATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Description and Operation > Operation-Cab/Chassis Models > Page 6171 EGR Temperature Sensor: Description and Operation Operation-Pick Up Models OPERATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). A temperature probe (1) is located at the end of the sensor assembly (3). The EGR temperature sensor is a negative temperature coefficient thermistor used to measure the temperature of the EGR gas flow after it exits the EGR cooler. The ECM (Engine Control Module) supplies 5-volts to the EGR temperature signal circuit. To determine the temperature of the EGR gas flow, the ECM monitors the change in voltage caused by changes in the resistance of the sensor. The ECM uses the exhaust gas recirculation temperature value for the engine protection system, and also for engine emissions control. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal EGR Temperature Sensor: Service and Repair Removal Removal-Cab/Chassis Models REMOVAL-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near EGR valve. 1. Disconnect electrical connector (2) at sensor. 2. Remove sensor (1) from EGR tube (6). Removal-Pick Up Models REMOVAL-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6174 1. If equipped, remove four cover bolts (2) and remove EGR crossover tube cover (1). 2. If equipped, remove EGR valve cover (2). 3. A pigtail wiring harness connects sensor to engine wiring harness. 4. Unscrew nut (2) at intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6175 5. Disconnect sensor pigtail harness electrical connector from engine wiring harness and remove sensor assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6176 EGR Temperature Sensor: Service and Repair Installation Installation-Cab/Chassis Models INSTALLATION-CAB/CHASSIS MODELS The EGR Temperature Sensor (1) is located on the EGR crossover tube (6) near the EGR valve. 1. Clean EGR crossover tube at sensor mounting point. 2. Check condition of the sensors metal gasket and replace if necessary. 3. Install sensor (1) to EGR tube (6). Tighten to 18 Nm (13 ft. lbs.). 4. Connect electrical connector (2) to sensor. Installation-Pick Up Models INSTALLATION-PICK UP MODELS The EGR Temperature Sensor (1) is located on the intake manifold, below, and to the rear of the EGR valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6177 1. A pigtail wiring harness (3) connects the sensor to the engine wiring harness. 2. Position sensor probe (1) into intake manifold. 3. Screw and tighten nut (2) into intake manifold. 4. Connect electrical connector (4) to engine wiring harness. 5. Install EGR valve cover (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Removal > Page 6178 6. Install EGR crossover tube cover (1) and four cover bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Description and Operation Exhaust Pressure Differential Sensor: Description and Operation DESCRIPTION The Exhaust Differential Pressure Sensor is remotely mounted on the transmission housing. Two pressure tubes measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Differential Sensor: Service and Repair Removal REMOVAL 1. Raise and support vehicle. 2. Disconnect electrical connector. 3. Disconnect hoses at pressure differential pressure sensor. 4. Remove mounting bolt and differential pressure sensor. 5. Remove mounting bolts (1). PRESSURE DIFFERENTIAL TUBING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 6184 6. Remove pressure differential pressure tubing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 6185 Exhaust Pressure Differential Sensor: Service and Repair Installation INSTALLATION PRESSURE DIFFERENTIAL TUBING 1. Install differential pressure tubing, if removed. Tighten fittings to 30 Nm (22 ft. lbs.). 2. Position differential pressure sensor (1). 3. Install mounting nuts (5) and bolts. Tighten to 10 Nm (89 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Removal > Page 6186 NOTE: Make sure there is not a dip in the pressure differential hoses. 4. Install hose (2) to the rear DPF tubing. 5. Install hose (3) to the front DPF tubing. 6. Connect electrical connector (6). 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal Pressure Feedback Exhaust Sensor: Service and Repair Removal REMOVAL 1. Disconnect exhaust gas pressure sensor electrical connector (1). 2. Using a 6 point deepwell socket, remove exhaust gas sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Removal > Page 6191 Pressure Feedback Exhaust Sensor: Service and Repair Installation INSTALLATION 1. Using a 6 point deepwell socket, install exhaust gas pressure sensor. 2. Tighten sensor to 18 Nm (13 ft. lbs.). 3. Connect exhaust gas pressure sensor electrical connector (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder. Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6198 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than +/- 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6199 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed Information Not Supplied by the Manufacturer Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6206 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6207 Accelerator Pedal Position Sensor: Diagrams Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6208 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 6211 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 6214 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal Air Filter Element: Service and Repair Removal REMOVAL There is no longer a Filter Minder on the MY08 Diesel Engines. There will be an EVIC message which will display when the filter restriction reaches it's maximum. The customer will be required to replace it with-in 250 miles (402 KM) Filter Removal 1. The housing cover is equipped with spring clips and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal. 2. Remove air cleaner element from air cleaner housing (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 6220 Air Filter Element: Service and Repair Installation INSTALLATION 1. Before installing new air cleaner element (filter), clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6224 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6225 Air Flow Meter/Sensor: Diagrams Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6226 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6227 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 6230 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control Fuel Inlet Metering Valve: Locations Actuator-Fuel Control Component ID: 4 Component : ACTUATOR-FUEL CONTROL Connector: Name : ACTUATOR-FUEL CONTROL Color : # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER Pin Circuit Description 1 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 2 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 2 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control > Page 6236 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control > Page 6237 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Actuator-Fuel Control > Page 6238 Fuel Inlet Metering Valve: Locations Fuel Control Actuator DESCRIPTION The Fuel Control Actuator (FCA) (3) is located at the rear of the high-pressure, fuel injection pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Page 6239 Fuel Inlet Metering Valve: Diagrams Component ID: 4 Component : ACTUATOR-FUEL CONTROL Connector: Name : ACTUATOR-FUEL CONTROL Color : # of pins : 2 Qualifier : (DIESEL) Pin Circuit Description 1 K604 18BR/TN FUEL CONTROL ACTUATOR DRIVER Pin Circuit Description 1 K365 18DB/BR FUEL CONTROL ACTUATOR DRIVER 2 K65 18BR/LB FUEL CONTROL ACTUATOR RETURN 2 K366 18BR/LB FUEL CONTROL ACTUATOR RETURN Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Page 6240 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Locations > Page 6241 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Description and Operation > Fuel Control Actuator Fuel Inlet Metering Valve: Description and Operation Fuel Control Actuator Description DESCRIPTION The Fuel Control Actuator (FCA) (3) is located at the rear of the high-pressure, fuel injection pump. Operation OPERATION The Fuel Control Actuator (FCA) is an electronically controlled solenoid valve. The ECM controls the amount of fuel that enters the high-pressure pumping chambers by opening and closing the FCA based on a demanded fuel pressure. When the FCA is opened, the maximum amount of fuel is being supplied to the fuel injection pump. Any fuel that does not enter the injection pump is directed to the cascade overflow valve. The cascade overflow valve regulates how much excess fuel is used for lubrication of the pump and how much is returned to the fuel tank through the drain manifold. An audible click from the FCA is normal when operating the key from the ON to the OFF position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Description and Operation > Fuel Control Actuator > Page 6244 Fuel Inlet Metering Valve: Description and Operation Cascade Overflow Valve Description DESCRIPTION NOTE: The cascade overflow valve is not serviced separately. The cascade overflow valve (4) is located on the top/rear side of the fuel injection pump. Operation OPERATION When the fuel control actuator (FCA) is opened, the maximum amount of fuel is being delivered to the fuel injection pump. The cascade valve regulates how much excess fuel is used for lubrication of the injection pump, and is also used to route excess fuel through the drain circuit and back into the fuel tank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Service and Repair > Removal Fuel Inlet Metering Valve: Service and Repair Removal REMOVAL 1. Remove electrical connector (6) from Fuel Control Actuator (FCA). 2. Remove FCA mounting screws (1). 3. Twist and pull FCA to remove from injection pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Fuel Inlet Metering Valve, Diesel > Component Information > Service and Repair > Removal > Page 6247 Fuel Inlet Metering Valve: Service and Repair Installation INSTALLATION 1. Lubricate new Fuel Control Actuator (FCA) O-ring with clean oil before installation. 2. Turn FCA in a clockwise direction while pressing it into machined bore on rear of fuel injection pump. Be sure FCA flange is flush with the mounting surface on fuel injection pump. 3. Install FCA mounting screws (1) by hand. 4. Tighten FCA mounting screws (1) to 7 Nm (62 in. lbs). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Description and Operation Fuel: Description and Operation FUEL REQUIREMENTS - DIESEL ENGINE WARNING: Do not use alcohol or gasoline as a fuel blending agent. They can be unstable under certain conditions and hazardous or explosive when mixed with diesel fuel. Use good quality diesel fuel from a reputable supplier. It is recommended that purchase of diesel fuel should be made from a service station that is known to dispense a high volume of highway diesel fuel. - Ultra Low Sulfur Highway Diesel Fuel (15 ppm of sulfur or less) is required to be used in Dodge Ram Trucks equipped with 6.7L diesel engine Ultra Low Sulfur Highway Diesel Fuel (preferred) or Low Sulfur Highway Diesel Fuel (500 ppm of sulfur or less) are required to be used in Dodge Ram Trucks equipped with a 5.9L diesel engine. - A maximum blend of 5% biodiesel, or less, is acceptable as long as the biodiesel mixture meets ASTM specification D-975. A biodiesel fuel blend that is higher then 5% is not acceptable because these higher percentage biodiesel blends contain excess amounts of NUMBER: W14-12-6 GROUP Fuel DATE: Approval Pending moisture which exceed the water stripping capability of the on-engine final fuel filter. Should higher percentage biodiesel fuels be used an auxilliary water stripping filter will be required. No off-highway diesel fuel i.e. farm or marine use diesel fuel is acceptable due to unknown sulfur and water content and unknown cetane number. Unknown fuel quality may adversely effect the performance of the engine and fuel injection system. Fuel conditioners (additives) are not recommended and should not be required if you buy good quality fuel and follow cold weather advice supplied in your Owners Manual. Diesel fuel is seldom completely free of water. To prevent fuel system trouble, including fuel line freezing in winter, drain the accumulated water from the fuel/water separator using the fuel/water separator drain provided. If you buy good-quality fuel and follow the cold-weather advice above, fuel conditioners should not be required in your vehicle. If available in your area, a high cetane "premium" diesel fuel may offer improved cold starting and warm-up performance. Proper Bulk (Off-Vehicle) Fuel Storage Proper maintenance of stored fuel is essential. Diesel fuel is seldom entirely free of moisture. Fuel contaminated with moisture may develop a bacteria or "slime" that may restrict or block fuel filters and lines. As diesel fuel is lighter than water, drain condensation no less than monthly from the diesel fuel supply/storage tanks. Change the storage tank in-line filter regularly. This filter acts as a last filter prior to the diesel fuel entering the vehicle diesel fuel tank. Good quality diesel fuel is mandatory. If the storage tank does not have an in-line filter, then a in-line filter should be added. Proper On-vehicle Fuel Storage And Filtering Proper on-vehicle fuel storage that prevents fuel contamination is important. Primary filtering of the diesel fuel is performed by the original (OEM) vehicle fuel tank pickup filter. The original (OEM) vehicle fuel tank module (fuel pickup) filter performs a primary filtering of the on-vehicle diesel fuel as the fuel leaves the fuel tank and enters the fuel lines. On-vehicle auxiliary diesel fuel tanks are often added by the vehicle owner to extend vehicle driving range. Auxiliary fuel tank systems must protect the quality of the diesel fuel just as well as the originally equipped (OEM) fuel tank that came with the vehicle when it was new. On-vehicle auxiliary diesel fuel storage tanks must have a primary fuel filter to prevent contamination and moisture accumulation. The prevention of moisture in the fuel system, the prevention of fuel stagnation, and the use of a primary fuel filter should all be considered in the purchase, installation, and maintenance of any auxiliary on-vehicle diesel fuel tank. Proper On-vehicle Final Fuel Filtering The large fuel filter that is mounted on the engine is the final fuel filter, water separator, fuel heater, and water drain. This filter is the final "line of defense" when maintaining a high level of fuel quality. If the diesel fuel is contaminated or contains moisture, the engine mounted fuel filter system is the last chance to affect possible correction. The quality of the fuel, its prior fuel storage, and fuel handling prior to the final filter all have a significant impact on the amount of contaminates and moisture entering the final fuel filter. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Description and Operation > Page 6251 It is important to drain moisture/water at least monthly from the final fuel filter. Do not wait until the "Water In Fuel" indicator illuminates before performing this maintenance. Drain accumulated water frequently. Maintenance on the final fuel filter / water separator is important. Follow the maintenance schedule per your Owners Manual. Replace the filter more frequently if highly contaminated or high moisture fuel is encountered. On a 5.9L engine, if the final fuel filter is replaced due to a high moisture content diesel fuel, then verify that the water sensor in the final filter has been cleaned. Excessive moisture may contaminate the sensor sensing probes. The 6.7L engine includes a new water in fuel sensor with the new final fuel filter element. The final fuel / water separator filter must meet or exceed OEM specifications. Some aftermarket filters may not meet OEM specifications. The final fuel / water separator filter must meet or exceed the filtration specifications listed in the table below. Final fuel / water separator filters that meet the above specifications in the table above are approved for use on Cummins 5.9L and 6.7L diesel engines. The use of non-approved fuel filters will result in engine performance deterioration, and/or possible progressive damage to the engine from foreign particle ingestion, and/or fuel system component corrosion. NOTE: DAMAGES CAUSED BY THE USE OF FUEL FILTERS NOT APPROVED BY DAIMLERCHRYSLER MAY NOT BE COVERED BY THE NEW ENGINE WARRANTY. It is recommended that customers use the MOPAR approved or Cummins Equivalent fuel filters to protect the engine from debris ingestions and water contamination. The following final fuel / water separator filters are known to meet or exceed the specifications listed in the table above. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description Fuel Filler Cap: Description and Operation Description DESCRIPTION The plastic fuel tank filler tube cap is threaded onto the end of the fuel fill tube. Certain models are equipped with a 1/4 turn cap. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description > Page 6256 Fuel Filler Cap: Description and Operation Operation OPERATION The loss of any fuel or vapor out of fuel filler tube is prevented by the use of a pressure-vacuum fuel fill cap. Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. CAUTION: Remove fill cap before servicing any fuel system component to relieve tank pressure. If equipped with an ORVR system and an ESIM switch, the cap must be tightened securely. If cap is left loose, a Diagnostic Trouble Code (DTC) may be set. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation > Description Fuel Filler Cap Warning Indicator: Description and Operation Description DESCRIPTION A gas cap indicator is standard equipment on all instrument clusters. However, on vehicles equipped with the optional diesel engine, this indicator is electronically disabled. The gas cap indication appears within the odometer Vacuum Fluorescent Display (VFD) unit. The gas cap indicator consists of a textual gASCAP message which appears in place of the odometer/trip odometer information in the display. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The gas cap textual message appears in the same blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The gas cap indicator is serviced as a unit with the VFD in the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation > Description > Page 6261 Fuel Filler Cap Warning Indicator: Description and Operation Operation OPERATION The gas cap indicator gives an indication to the vehicle operator when there is a gross leak detected in the on-board fuel vapor recovery system. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The gas cap indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD gas cap indication will always be OFF when the ignition switch is in any position except ON or START. The instrument cluster will turn ON the gas cap indicator for the following reasons: - Gas Cap Indicator Lamp-On Message - Each time the cluster receives an electronic gas cap indicator lamp-ON message from the PCM indicating there is a gross leak in the vapor recovery system, the gas cap indicator will be illuminated. If the ignition switch is in the ON position and the vehicle is not moving when the message is received, the VFD will repeatedly and sequentially cycle the gas cap indication in two second intervals with the odometer/trip odometer information and any other active textual warnings. If the vehicle is moving, or once the cluster of a non-moving vehicle receives an electronic vehicle speed message from the PCM indicating a speed greater than zero, the warning sequence will consist of three complete display cycles with an audible single chime tone accompanying each cycle, then revert to only the visual gas cap indication and odometer/trip odometer display cycling until the cluster receives a message indicating there is no gross leak in the vapor recovery system, or until the ignition switch is turned to the OFF position, whichever occurs first. The VFD can be reverted to the odometer display and any currently displayed textual messages suspended by momentarily depressing and releasing the odometer/trip odometer reset switch button on the front of the cluster. The PCM continually monitors the on board vapor recovery system to determine whether there are air leaks in the system. The PCM then sends the proper electronic messages to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the EMIC turns ON the gas cap indicator due to a monitored gross leak in the vapor recovery system, it may indicate that the gas cap has been removed or is improperly installed. For proper diagnosis of the on board vapor recovery system, the PCM, the EMIC, the CAN data bus or the electronic communication related to gas cap indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Filter: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 6266 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 6267 Fuel Filter: Technical Service Bulletins Fuel System - Severe Duty Filtration Kit Availability NUMBER: 14-001-09 GROUP: Fuel DATE: January 24, 2009 SUBJECT: Severe Duty Fuel Filtration Mopar Add On Kit Available MODELS: 2005 - 2009 (D1/DH) Ram Truck (2500/3500 Pick Up) 2007 - 2009 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH vehicles equipped with a 5.9L Cummins engine built from 2005 model year and D1/DH/DC vehicles equipped with a 6.7L Cummins engine built from 2007 model year. DISCUSSION: A frame mounted supplemental filter kit is now available for the vehicles listed above. This kit includes complete instructions (K6855569AC) with all necessary components and wiring to upgrade fuel filtering to a severe duty rating. NOTE: The maintenance intervals for the fuel filters (on engine filter and added chassis mounted severe duty fuel filtration kit filter) are 15,000 miles. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Description and Operation > Description Fuel Filter: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Description and Operation > Description > Page 6270 Fuel Filter: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel Filter/Water Separator Removal/Installation. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal Fuel Filter: Service and Repair Removal REMOVAL Refer to maintenance schedules, for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6273 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6274 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6275 Fuel Filter: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. Refer to Standard Procedures-Fuel System Priming. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6276 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Removal > Page 6277 a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations Fuel Heater: Locations Component ID: 142 Component : HEATER-FUEL Connector: Name : HEATER-FUEL Color : # of pins : 2 Qualifier : (DIESEL) A Z902 14BK GROUND A Z816 14BK GROUND B A961 14RD FUEL HEATER CONTROL OUTPUT Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6281 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6282 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6283 Fuel Heater: Diagrams Component ID: 142 Component : HEATER-FUEL Connector: Name : HEATER-FUEL Color : # of pins : 2 Qualifier : (DIESEL) A Z902 14BK GROUND A Z816 14BK GROUND B A961 14RD FUEL HEATER CONTROL OUTPUT Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6284 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6285 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6286 Fuel Heater: Description and Operation OPERATION The fuel heater is used to prevent diesel fuel from waxing during cold weather operation. When the fuel temperature is below 45° ±8 F (7°C), the temperature sensor allows current to flow to the heater element warming the fuel. When the fuel temperature is above 75° ±8 F (24°C), the sensor stops current flow to the heater element. Battery voltage to operate the fuel heater element is supplied from the ignition switch and through a solid stated device in the TIPM. The fuel heater element and "solid state device in TIPM" are not computer controlled. The heater element operates on 12 volts, 300 watts at 0° F (-18° C). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Locations > Page 6287 Fuel Heater: Testing and Inspection FUEL HEATER The fuel heater is used to prevent diesel fuel from waxing during cold weather operation. NOTE: The fuel heater element, "solid state device in TIPM" is not controlled by the Engine Control Module (ECM). A malfunctioning fuel heater can cause a wax build-up in the fuel filter/water separator. Wax build-up in the filter/separator can cause engine starting problems and prevent the engine from revving up. It can also cause blue or white fog-like exhaust. If the heater is not operating in cold temperatures, the engine may not operate due to fuel waxing. The fuel heater assembly is located on the side of fuel filter housing and internal to the fuel filter housing. The heater assembly is equipped with a built-in fuel temperature sensor (thermostat) that senses fuel temperature. When fuel temperature drops below 45 ° ± 8° F (7° C), the sensor allows current to flow to built-in heater element to warm fuel. When fuel temperature rises above 75 °± 8° F (24° C), the sensor stops current flow to heater element (circuit is open). Voltage to operate fuel heater element is supplied from ignition switch, through "solid state device in TIPM", to fuel temperature sensor and on to fuel heater element. The heater element operates on 12 volts, 300 watts at 0 °F (-18° C). As temperature increases, power requirements decrease. A minimum of 7 volts is required to operate the fuel heater. The resistance value of the heater element is less than 1 ohm (cold) and up to 1000 ohms warm. TESTING 1. Disconnect electrical connector (1) from heater element. Ambient temperature must be below the circuit close temperature. If necessary, induce this ambient temperature by placing ice packs on thermostat to produce an effective ambient temperature below circuit close temperature. Measure resistance across two pins. Operating range is 0.3 - 0.45 Ohms. 2. If resistance is out of range, replace heater element. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Service and Repair > Removal Fuel Heater: Service and Repair Removal REMOVAL Refer to maintenance schedules, for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Service and Repair > Removal > Page 6290 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Service and Repair > Removal > Page 6291 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Service and Repair > Removal > Page 6292 Fuel Heater: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Service and Repair > Removal > Page 6293 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Service and Repair > Removal > Page 6294 a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 Fuel Injector: Locations Injector-Fuel 1 Component ID: 148 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K611 14BK INJECTOR HIGH SIDE DRIVER NO. 1 2 K11 14BK INJECTOR CONTROL NO. 1 Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6299 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6300 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6301 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K11 18BR/YL INJECTOR CONTROL NO. 1 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6302 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6303 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6304 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6305 Fuel Injector: Locations Injector-Fuel 2 Component ID: 149 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K612 14BK INJECTOR HIGH SIDE DRIVER NO. 2 2 K12 14BK INJECTOR CONTROL NO. 2 Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6306 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6307 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6308 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K12 18BR/DB INJECTOR CONTROL NO. 2 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6309 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6310 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6311 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6312 Fuel Injector: Locations Injector-Fuel 3 Component ID: 150 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K613 14BK INJECTOR HIGH SIDE DRIVER NO. 3 2 K13 14BK INJECTOR CONTROL NO. 3 Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6313 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6314 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6315 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K13 18BR/LB INJECTOR CONTROL NO. 3 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6316 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6317 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6318 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6319 Fuel Injector: Locations Injector-Fuel 4 Component ID: 151 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K229 14BK INJECTOR HIGH SIDE DRIVER-BANK 2 Pin Circuit Description 1 K614 14BK INJECTOR HIGH SIDE DRIVER NO. 4 2 K14 14BK INJECTOR CONTROL NO. 4 Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6320 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6321 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6322 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K14 18BR/TN INJECTOR CONTROL NO. 4 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6323 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6324 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6325 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6326 Fuel Injector: Locations Injector-Fuel 1 Component ID: 148 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K611 14BK INJECTOR HIGH SIDE DRIVER NO. 1 2 K11 14BK INJECTOR CONTROL NO. 1 Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6327 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6328 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6329 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K11 18BR/YL INJECTOR CONTROL NO. 1 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6330 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6331 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6332 Injector-Fuel 2 Component ID: 149 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6333 Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K612 14BK INJECTOR HIGH SIDE DRIVER NO. 2 2 K12 14BK INJECTOR CONTROL NO. 2 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6334 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6335 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K12 18BR/DB INJECTOR CONTROL NO. 2 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6336 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6337 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6338 Injector-Fuel 3 Component ID: 150 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6339 Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K613 14BK INJECTOR HIGH SIDE DRIVER NO. 3 2 K13 14BK INJECTOR CONTROL NO. 3 Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6340 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6341 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K13 18BR/LB INJECTOR CONTROL NO. 3 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6342 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6343 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6344 Injector-Fuel 4 Component ID: 151 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6345 Pin Circuit Description 1 K229 14BK INJECTOR HIGH SIDE DRIVER-BANK 2 Pin Circuit Description 1 K614 14BK INJECTOR HIGH SIDE DRIVER NO. 4 2 K14 14BK INJECTOR CONTROL NO. 4 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6346 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6347 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K14 18BR/TN INJECTOR CONTROL NO. 4 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6348 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6349 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6350 Injector-Fuel 5 Component ID: 152 Component : INJECTOR-FUEL 5 Connector: Name : INJECTOR-FUEL 5 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6351 Pin Circuit Description 1 K229 14BK INJECTOR HIGH SIDE DRIVER-BANK 2 Pin Circuit Description 1 K638 14BK INJECTOR HIGH SIDE DRIVER NO. 5 2 K38 14BK INJECTOR CONTROL NO. 5 Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6352 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6353 Connector: Name : INJECTOR-FUEL 5 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K38 18BR/OR INJECTOR CONTROL NO. 5 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6354 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6355 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6356 Injector-Fuel 6 Component ID: 153 Component : INJECTOR-FUEL 6 Connector: Name : INJECTOR-FUEL 6 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6357 Pin Circuit Description 1 K229 14BK INJECTOR HIGH SIDE DRIVER-BANK 2 Pin Circuit Description 1 K658 14BK INJECTOR HIGH SIDE DRIVER NO. 6 2 K58 14BK INJECTOR CONTROL NO. 6 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6358 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6359 Connector: Name : INJECTOR-FUEL 6 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K58 18BR/VT INJECTOR CONTROL NO. 6 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6360 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6361 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Injector-Fuel 1 > Page 6362 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 Fuel Injector: Diagrams Injector-Fuel 1 Component ID: 148 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K611 14BK INJECTOR HIGH SIDE DRIVER NO. 1 2 K11 14BK INJECTOR CONTROL NO. 1 Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6365 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6366 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6367 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K11 18BR/YL INJECTOR CONTROL NO. 1 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6368 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6369 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6370 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6371 Fuel Injector: Diagrams Injector-Fuel 2 Component ID: 149 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K612 14BK INJECTOR HIGH SIDE DRIVER NO. 2 2 K12 14BK INJECTOR CONTROL NO. 2 Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6372 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6373 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6374 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K12 18BR/DB INJECTOR CONTROL NO. 2 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6375 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6376 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6377 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6378 Fuel Injector: Diagrams Injector-Fuel 3 Component ID: 150 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K613 14BK INJECTOR HIGH SIDE DRIVER NO. 3 2 K13 14BK INJECTOR CONTROL NO. 3 Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6379 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6380 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6381 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K13 18BR/LB INJECTOR CONTROL NO. 3 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6382 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6383 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6384 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6385 Fuel Injector: Diagrams Injector-Fuel 4 Component ID: 151 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K229 14BK INJECTOR HIGH SIDE DRIVER-BANK 2 Pin Circuit Description 1 K614 14BK INJECTOR HIGH SIDE DRIVER NO. 4 2 K14 14BK INJECTOR CONTROL NO. 4 Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6386 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6387 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6388 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K14 18BR/TN INJECTOR CONTROL NO. 4 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6389 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6390 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6391 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6392 Fuel Injector: Diagrams Injector-Fuel 1 Component ID: 148 Component : INJECTOR-FUEL 1 Connector: Name : INJECTOR-FUEL 1 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K611 14BK INJECTOR HIGH SIDE DRIVER NO. 1 2 K11 14BK INJECTOR CONTROL NO. 1 Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6393 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6394 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6395 Connector: Name : INJECTOR-FUEL 1 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K11 18BR/YL INJECTOR CONTROL NO. 1 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6396 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6397 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6398 Injector-Fuel 2 Component ID: 149 Component : INJECTOR-FUEL 2 Connector: Name : INJECTOR-FUEL 2 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6399 Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K612 14BK INJECTOR HIGH SIDE DRIVER NO. 2 2 K12 14BK INJECTOR CONTROL NO. 2 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6400 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6401 Connector: Name : INJECTOR-FUEL 2 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K12 18BR/DB INJECTOR CONTROL NO. 2 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6402 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6403 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6404 Injector-Fuel 3 Component ID: 150 Component : INJECTOR-FUEL 3 Connector: Name : INJECTOR-FUEL 3 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6405 Pin Circuit Description 1 K227 14BK INJECTOR HIGH SIDE DRIVER-BANK 1 Pin Circuit Description 1 K613 14BK INJECTOR HIGH SIDE DRIVER NO. 3 2 K13 14BK INJECTOR CONTROL NO. 3 Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6406 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6407 Connector: Name : INJECTOR-FUEL 3 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K13 18BR/LB INJECTOR CONTROL NO. 3 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6408 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6409 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6410 Injector-Fuel 4 Component ID: 151 Component : INJECTOR-FUEL 4 Connector: Name : INJECTOR-FUEL 4 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6411 Pin Circuit Description 1 K229 14BK INJECTOR HIGH SIDE DRIVER-BANK 2 Pin Circuit Description 1 K614 14BK INJECTOR HIGH SIDE DRIVER NO. 4 2 K14 14BK INJECTOR CONTROL NO. 4 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6412 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6413 Connector: Name : INJECTOR-FUEL 4 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K14 18BR/TN INJECTOR CONTROL NO. 4 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6414 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6415 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6416 Injector-Fuel 5 Component ID: 152 Component : INJECTOR-FUEL 5 Connector: Name : INJECTOR-FUEL 5 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6417 Pin Circuit Description 1 K229 14BK INJECTOR HIGH SIDE DRIVER-BANK 2 Pin Circuit Description 1 K638 14BK INJECTOR HIGH SIDE DRIVER NO. 5 2 K38 14BK INJECTOR CONTROL NO. 5 Component Location - 8 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6418 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6419 Connector: Name : INJECTOR-FUEL 5 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K38 18BR/OR INJECTOR CONTROL NO. 5 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 8 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6420 Component Location - 9 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6421 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6422 Injector-Fuel 6 Component ID: 153 Component : INJECTOR-FUEL 6 Connector: Name : INJECTOR-FUEL 6 Color : # of pins : 2 Qualifier : (DIESEL) Gender : MALE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6423 Pin Circuit Description 1 K229 14BK INJECTOR HIGH SIDE DRIVER-BANK 2 Pin Circuit Description 1 K658 14BK INJECTOR HIGH SIDE DRIVER NO. 6 2 K58 14BK INJECTOR CONTROL NO. 6 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6424 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6425 Connector: Name : INJECTOR-FUEL 6 Color : BLACK # of pins : 2 Qualifier : (NGC) Pin Circuit Description 1 K58 18BR/VT INJECTOR CONTROL NO. 6 2 K342 16BR/WT ASD CONTROL OUTPUT Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6426 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6427 Component Location - 15 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Injector-Fuel 1 > Page 6428 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injector - Description Fuel Injector: Description and Operation Fuel Injector - Description DESCRIPTION Six individual, solenoid actuated high-pressure fuel injectors are used (6). The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors (13), mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line (1). FUEL INJECTOR ID CORRECTION CODES: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injector - Description > Page 6431 Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. The valve cover and valve cover gasket will need to be removed in order to manually record the values from the original injectors. Contact cleaner or brake cleaner may be used to clean the fuel injector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Fuel Injector - Description > Page 6432 Fuel Injector: Description and Operation Fuel Injector - Operation OPERATION High-pressure fuel is supplied from the injection pump, through a high-pressure fuel line, into a fuel rail, through high-pressure lines, through steel connectors and into the solenoid actuated fuel injector. The ECM actuates the solenoid causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber. Each fuel injector is connected to the fuel rail by a high-pressure fuel line and a steel connector. This steel connector is positioned into the cylinder head and sealed with an O-ring. The connector is retained in the cylinder head by a nut (fitting) that is threaded into the cylinder head. The torquing force of this threaded nut (fitting) provides a sealing pressure between the fuel line connector and the fuel injector. Retaining nut torque is very critical. If the nut (fitting) is under torqued, the mating surfaces will not seal and a high-pressure fuel leak will result. If the fitting is over torqued, the connector and injector will deform and also cause a high-pressure fuel leak. This leak will be inside the cylinder head and will not be visible. The result will be a possible fuel injector miss-fire and low power, or a no-start condition. The fuel injectors use hole type nozzles. High-pressure flows into the side of the injector, the ECM activates the solenoid causing the injector needle to lift and fuel to be injected. The clearances in the nozzle bore are extremely small and any dirt or contaminants will cause the injector to stick. Because of this, it is very important to do a thorough cleaning of any lines before opening up any fuel system component. Always cover or cap any open fuel connections before a fuel system repair is performed. Each fuel injector connector tube contains an edge filter that is designed to break up small contaminants before entering the fuel injector. The edge filters are not a substitute for proper cleaning and covering of all fuel system components during repair. The bottom of each fuel injector is sealed to the cylinder head with a 1.5mm thick copper shim (gasket). The correct thickness shim must always be re-installed after removing an injector. Fuel pressure in the injector circuit decreases after injection. The injector needle valve is immediately closed and fuel flow into the combustion chamber is stopped. Exhaust gases are prevented from entering the injector nozzle by the needle valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Page 6433 Fuel Injector: Testing and Inspection *INJECTOR RETURN FLOW TEST 1. ENGINE RUNS NOTE: Review Warranty bulletin D-05-24. NOTE: Battery charger may be utilized if cranking speed is below 170 RPM's. Does the engine run? Yes - Go To 2 No - Go To 3 2. * INJECTOR RETURN FLOW TEST @ 1200 RPM AND 1400 BAR RAIL PRESSURE 1. Operate the engine until the coolant temperature is above 180° F. 2. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing. 3. Install fuel system test fitting 9012 in place of the banjo connector. 4. Remove the vehicle fuel return line from the engine fuel drain tube. 5. Install a piece of fuel line onto the test fitting and into a fuel container or into the fuel tank. 6. Install one end of a test hose onto the fuel drain tube. Place the other end of the test hose into a graduated cylinder. 7. Start engine and allow to idle for 30 sec. This step allows the flows to stabilize. Gather appropriate measuring device to measure collected return fuel. 8. Using the scan tool, navigate to ECM view -> PCM Cummins -> More Options-> System Tests -> Fuel Pressure override test. Select Start, then press Next. 9. Press the Run button on the screen. As you press the Run button to start the overpressure test, please move the injector return hose from the bucket and insert into the appropriate measuring device. The engine speed will elevate rapidly to 1200 rpm and the rail pressure will increase to 20000 psi (1400 bar). 10. While the test is running, please record the FCA duty cycle % and actual rail pressure record the readings on the Cummins Diesel Diagnostic Worksheet located under e-files, service, Star center in dealerconnect. 11. Measure and Record the amount of fuel collected. 12. If the flow is less than 160 ml/30 secs, the test has successfully passed, and the condition has been fixed 13. If the flow is greater than 250 ml/30 seconds, refer to step 20. 14. If the flow is greater than 160 ml/30 secs after step 11, shut off the engine and remove all 6 high pressure fuel lines. Re-torque the high-pressure connector nut. Inspect for damage, repair/replace as necessary. Reinstall high pressure fuel lines. 15. Start the engine and perform steps 7 through 10. 16. Measure the amount of fuel in the graduated cylinder. 17. If the amount of fuel is greater than 160 ml/30 sec, shut off the engine and remove the #1 high pressure fuel line. Cap the #1 fuel port using tool 9011 on the fuel rail and repeat steps 7 through 10. 18. Measure the amount of fuel in the graduated cylinder. If the amount is less than 160 ml.30 sec, remove and replace the #1 injector and #1 High pressure connector. 19. If the amount of fuel is not less than 160-ml/30 secs, repeat steps 17-18 for cylinders 2-6. 20. If the amount of fuel is greater than 250 ml/30 secs it is recommended that all 6 injectors be replaced. 21. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-12 to confirm repair. SPECIFICATION: Less than 160 ml/ 30 seconds total fuel returns flow Repair - Test Complete. 3. * INJECTOR RETURN FLOW TEST DURING ENGINE CRANKING @200 RPM WHEN THE VEHICLE WILL NOT START 1. Install 9012 fitting in standard location on back of fuel filter head to measure pump and injector return flows. 2. Install hoses to the test fitting and the injector return line and route them to a bucket or other container. Make sure test lines are straight and slope downward their entire length. This is to avoid trapping air/fuel in the lines while testing. 3. Unplug the injector harnesses at the valve cover, Unplug the connector to the FCA. 4. Crank the engine for least 10 seconds until fuel starts to flow out of the pump and injector return hoses. Turn Key off when finished. 5. Let all the fuel drain out of each line before continuing. 6. Place the injector return hose into an appropriate measuring device. 7. Crank the engine for 10 seconds. Go from Keyoff to Crank back to Keyoff. Do not leave the ignition on between tests. 8. Let all of the fuel drain out of the injector hose. 9. Record the amount of injector return for a 10 sec crank. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Page 6434 10. Flow should be less than 40 ml for 10 seconds of cranking 11. If the flow is greater than 40 ml after step 10, remove the #1 fuel injector supply line. Re-torque the high-pressure connector nut. Cap the #1 fuel port using tool 9011 on the fuel rail. 12. Crank the engine and perform steps 7 through 9. 13. Measure the amount of fuel in the graduated cylinder. 14. If the amount of fuel is less than 40 ml, remove the #1 high pressure connector and the #1 fuel injector. Inspect for damage, repair/replace as necessary. 15. If the amount of fuel is not less than 40 ml, repeat steps 12-14 for cylinders 2-6. 16. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-12 to confirm repair. Repair - Note: DTC's will be set by this process. Remember to go in and clear all DTC's from all modules. Test complete. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal Fuel Injector: Service and Repair Fuel Injector - Removal REMOVAL FUEL INJECTOR ID CORRECTION CODES: Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. The valve cover and valve cover gasket will need to be removed in order to manually record the values from the original injectors. Contact cleaner or brake cleaner may be used to clean the fuel injector. NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code. NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded. CAUTION: Refer to Cleaning Fuel System Parts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 6437 Six individual, solenoid actuated high-pressure fuel injectors (7) are used. The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors, mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line. 1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables. 2. Remove vanity cover. 3. Remove breather assembly and tubes. 4. Remove valve cover. 5. Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 6438 6. An integrated fuel injector wire harness / valve cover gasket (2) is used. After all 12 nuts (1) have been removed, remove this integrated gasket. Before removing gasket, disconnect engine wiring harness at both electrical connectors (3). 7. Remove necessary high pressure fuel line connecting the necessary fuel injector rail to high pressure connector. 8. A connector retainer (nut) is used on each connector tube (12). Remove this nut(s) by unthreading from cylinder head. These nuts (12) hold the fuel injector retainers (13) to the fuel injector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 6439 9. Using special high-pressure connector removal tool #9015 (4) remove necessary high-pressure connector(s) from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head. 10. Remove 2 fuel injector hold-down clamp bolts (1) at each injector being removed. 11. Remove necessary exhaust rocker arm assembly(s). 12. USING TOOL #9010: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 6440 a. Special Tool #9010 is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2-piece mounting stud, and a pivoting handle.Do not attempt to remove the fuel injector with any other device. Damage to injector will occur. b. The rocker housing is bolted to the top of cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 5 rocker housing support bridges. c. Install and tighten 2-piece mounting stud to rocker housing. If removing the No. 6 fuel injector, separate the 2-piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half. d. Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action. e. Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head. f. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together. g. Be sure handle pivot nut is loose. h. Depress handle downward to remove fuel injector straight up from cylinder head bore. 13. Remove and discard injector sealing washer (2). This washer (2) should be located on tip of injector, or may have remained in the injector bore. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 6441 14. Measure sealing gasket (washer) (1). NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code. NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 6442 Fuel Injector: Service and Repair Fuel Injector - Installation INSTALLATION 1. Inspect fuel injector : a. Look for burrs on injector inlet. b. Check nozzle holes for hole erosion or plugging. c. Inspect end of nozzle for burrs or rough machine marks. d. Look for cracks at nozzle end. e. If any of these conditions occur, replace injector. 2. Record six-digit alphanumeric correction code located on the side of injector. 3. Inspect high-pressure fuel injector connector for : a. Damaged tip. b. Loose of missing alignment pin. c. Cut or missing O-ring. 4. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air. 5. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a certain thickness. A new shim (1) with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (1). Shim Thickness: 1.5 mm (.060") 6. Install new shim (1) (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation. 7. Install new O-ring to fuel injector. Apply small amount of clean engine oil to O-ring and injector bore. 8. Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage O-ring and seat injector. 9. Tightening Sequence: a. Install fuel injector holdown clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary tightening of these bolts to 5 Nm (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered. b. After tightening, relieve bolt torque, but leave both bolts threaded in place. c. Install high-pressure connector (13) and retaining nut (12). Do a preliminary tightening of nut (12) to 15 Nm (11 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 6443 d. Alternately tighten injector holdown bolts to 8 Nm (71 in. lbs.) torque. e. Do a final tightening of the high-pressure connector and retaining nut (12). Tighten to 50 Nm (37 ft. lbs.) torque. 10. Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components. 11. Install integrated gasket 12. Connect injector solenoid wires and nuts to top of injectors. Tighten connector nuts to 1.25 Nm (11 in. lbs.) torque. Be very careful not to overtighten these nuts as damage to fuel injector will occur. 13. Install exhaust rocker arm assembly. 14. Set exhaust valve lash. 15. Install fuel connector tube nut at cylinder head and tighten to 50 Nm (37 ft. lbs.). Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting. . 16. Install valve cover See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Removal and Replacement/Cylinder Head Cover - Installation . 17. Install breather assembly.FUEL INJECTOR ID CORRECTION CODES: Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM. 1. Connect negative battery cables to both batteries. 2. Programming Fuel Injector Correction Code: - Turn ignition switch "ON". - Using a diagnostic scan tool, select ECU View> PCM > MISCELLANEOUS FUNCTIONS. - Select Injector Quantity Adjustments and click Start. - Choose appropriate cylinder number and click next. - Click on Show Keyboard. NOTE: A fault code will be set if incorrect serialization codes have been inputted. - Input six-digit Injector Correction Code and click enter. - Review code as it was typed, then click Next if correct, or edit if necessary. - Repeat the preceding steps for other cylinders if necessary. - Once all fuel injector correction codes are entered, cycle the ignition to complete. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation OPERATION Fuel pressure at the fuel rail is monitored by the fuel rail pressure sensor. If fuel pressure becomes excessive, the pressure limiting valve opens and vents excess fuel pressure vents through the fuel pressure limiting valve drain port. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal Fuel Pressure Regulator: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. The fuel pressure limiting valve (1) is screwed into the front of the fuel rail (2). The fuel pressure limiting valve drain port is located on the side of the fuel rail next to the limiting valve. The drain port is not serviceable. 1. Thoroughly clean area at pressure limiting valve (1). 2. To gain access to the limiting valve, the intake connection/EGR valve assembly must be removed. Loosen clamp (5) securing EGR crossover tube (6) to EGR valve. Also loosen opposite end of EGR crossover tube. Remove clamp from intake connection. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal > Page 6449 3. Remove six bolts (1) securing intake connection (2). Lift the entire EGR valve/intake connection up and to the side to gain access to fuel pressure limiting valve. 4. Discard gasket (3). 5. Remove pressure limiting valve from fuel rail. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service and Repair > Removal > Page 6450 Fuel Pressure Regulator: Service and Repair Installation INSTALLATION 1. Be sure both end of manifold and limiting valve mounting area are clean. 2. Lubricate O-ring on limiting valve with fresh diesel oil. Also lubricate limiting valve threads with fresh diesel oil. 3. Install valve (1) and torque to 100 Nm (74 ft. lbs.). To prevent leaks, valve MUST be tightened to prescribed torque. 4. Install new intake connection gasket (3). 5. Position EGR valve/intake connection and install six bolts. Tighten bolts to 24 Nm (18 ft. lbs.). 6. Install new EGR crossover tube gasket. Tighten crossover tube clamps to 10 Nm (88 in. lbs.). 7. Using a diagnostic scan tool, reset vale life by using the "Reset Two-Stage Dump Valve Accumulator" function in the PCM portion of the diagnostic tool 8. Start engine and check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations Component ID: 419 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 K915 18BR/WT FUEL RAIL SENSOR RETURN Pin Circuit Description 1 K916 18BR/OR SENSOR GROUND 2 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 3 F855 18PK/YL 5 VOLT SUPPLY Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6454 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6455 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6456 Fuel Pressure Sensor/Switch: Diagrams Component ID: 419 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 K915 18BR/WT FUEL RAIL SENSOR RETURN Pin Circuit Description 1 K916 18BR/OR SENSOR GROUND 2 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 3 F855 18PK/YL 5 VOLT SUPPLY Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6457 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6458 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6459 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 6462 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 6463 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components. 8. Start engine and check for fuel leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL PRESSURES Fuel Pump/Gear Pump (low pressure) ................................................................................................................................ 551.5 - 1241 KPA (80 - 180 psi) Injection Pump ..................................................................................................................................... ............................ 200 - 1800 bar (2900 - 26107 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test Fuel Pressure: Testing and Inspection Fuel Pump Return Flow Test *FUEL PUMP RETURN FLOW TEST 1. FUEL PUMP RETURN FLOW TEST Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive (above 185,00 kpa/26,831 psi). If it is, troubleshoot for excessive rail pressure first. Remove the banjo bolt from the pressure-limiting valve on the fuel rail. Install fuel system test fitting 9013 into the pressure-limiting valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container Perform the tests listed below to determine if the pressure-limiting valve is leaking. a. Operate the engine at idle and watch for fuel flow into the fuel container. b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container. If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete. NOTE: Do not drive the vehicle with any portion of this test kit installed Operate the engine until the engine is at operating temperature. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing Install fuel system test fitting 9012 in place of the banjo connector. Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder. Start the engine and let it idle for one minute. Measure the amount of fuel in the graduated cylinder. If the flow is less than 1000ml/minute at idle, the test has successfully passed. If the flow is greater than 1000ml/minute at idle, replace the fuel injection pump. Retest to confirm repair. View Repair Repair - Test Complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6470 Fuel Pressure: Testing and Inspection High Pressure Fuel Pump Performance Test *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST If the engine will run do the following: 1. Monitor rail pressure with scan tool while the engine is at idle. 2. Compare the fuel pressure set point with the actual fuel pressure reading. 3. If actual fuel pressure reading fluctuates more than +/- 500 psi from the set point, then replace the Fuel Control Actuator (FCA). NOTE: After the actuator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump. 4. Turn off engine. 5. Disconnect the FCA harness 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL If the engine is a no start do the following: 1. Remove fuel pump to rail high pressure fuel line. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4. 4. Disconnect the Fuel Control Actuator (FCA). 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel. 7. Crank the engine for three (3) 10 seconds intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 rpm cranking speed is 70mL Minimum fuel pump flow at 200 rpm cranking speed is 90mL Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pump Return Flow Test > Page 6471 Fuel Pressure: Testing and Inspection In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure *IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE 1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test. 2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component. 3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector. 4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter. 5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6 6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage. 7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness. 8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9. 9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness. 10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness. 11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12. 12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness. 13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness. 14. Reconnect the lift pump connector. FLOW TEST. 1. Remove the fuel pump supply banjo fitting from the fuel injection pump. 2. Install fuel system test fitting 9863 onto the end of the quick connect line going to the fuel injection pump. 3. Connect one end of a section of fuel hose to the test fitting. 4. Put the other end of the fuel hose into an empty fuel container. 5. Use the scan tool to actuate the fuel lift pump. 6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds. 7. Read and record the amount of fuel in the graduated cylinder after 10 seconds. 8. If you have more than 570ml in the graduated cylinder after 10 seconds, the test has successfully passed. 9. If you have less than 570ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest. 10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component. 11. If reading is still less than 570ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest. 12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix. Test complete Repair - Test complete. - Perform POWERTRAIN VERIFICATION TEST - 6.7L. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 Fuel Pump Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 6494 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation OPERATION The fuel rail is used as a distribution device to supply high-pressure fuel to the high-pressure fuel lines. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal Fuel Rail: Service and Repair Fuel Rail - Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. 1. Disconnect both negative battery cables at both batteries. Isolate ends of both cables. 2. Disconnect electrical connector at fuel pressure sensor (2). 3. Disconnect electrical connector at MAP sensor (3). 4. Disconnect necessary wiring harness retention clips from intake manifold. 5. Disconnect cables for intake air heater. 6. Remove fuel line (8). 7. Loosen fittings (9). CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS (11) ATTACHED TO A SEPARATE FITTING (12), USE A BACK-UP WRENCH ON FITTING (12). DO NOT ALLOW FITTING (12) TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT. 8. Loosen fittings (11) and remove all fuel lines (1). Note and mark position of each fuel line while removing. 9. Remove fuel line connecting injection pump to fuel rail. 10. Remove fuel injection rail mounting bolts (7). 11. Remove rail (6) from top of intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 6500 Fuel Rail: Service and Repair Fuel Rail - Installation INSTALLATION 1. Clean any dirt/debris from top of intake manifold and bottom of fuel rail. 2. Position fuel rail to top of manifold and install rail mounting bolts (7). Torque bolts to 24 Nm (18 ft. lbs.). CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS (11) ATTACHED TO A SEPARATE FITTING (12), USE A BACK-UP WRENCH ON FITTING (12). DO NOT ALLOW FITTING (12) TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT. 3. Install all high-pressure lines to rail. Torque fittings to 30 Nm (22 ft. lbs.). 4. Reposition wiring harness to intake elbow and install nut. 5. Install two new sealing washers to fuel limiting valve banjo bolt. Torque to 24 Nm (18 ft. lbs.). Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components. 6. Connect electrical connector to fuel pressure sensor (2). 7. Connect electrical connector to MAP sensor (3). 8. Install air intake heater cables. 9. Connect battery cables to both batteries. 10. Start engine and check for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Description Fuel Supply Line: Description and Operation Description DESCRIPTION Low-Pressure Lines Are: - the fuel supply line from fuel tank to fuel filter housing. - the fuel return line back to fuel tank. - the fuel drain (manifold) line at rear of cylinder head. - the fuel supply line from fuel filter to fuel injection pump. - the fuel injection pump return line. High-Pressure Lines Are: - the fuel line from fuel injection pump to fuel rail. - the six fuel lines from fuel rail up to injector connector tubes WARNING: High-pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 180,000 kpa (26,107 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Description > Page 6505 Fuel Supply Line: Description and Operation Operation OPERATION High-Pressure Lines CAUTION: The high-pressure fuel lines must be held securely in the brace. The lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. If lines are ever kinked or bent, they must be replaced. Use only the recommended lines when replacement of high-pressure fuel line is necessary. High-pressure fuel lines deliver fuel (under pressure) of up to approximately 180,000 kPa (26,107 PSI) from the injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated during the injection process. All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. WARNING: Use extreme caution when inspecting for high-pressure fuel leaks. Inspect for high-pressure fuel leaks with a sheet of cardboard. High fuel injection pressure can cause personal injury if contact is made with the skin. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 6506 Fuel Supply Line: Testing and Inspection HIGH-PRESSURE FUEL LINE LEAKS High-pressure fuel line leaks can cause starting problems and poor engine performance. WARNING: Due to extreme fuel pressures of up to 180,000 kpa (26,107 psi), use extreme caution when inspecting for high-pressure fuel leaks. Do not get your hand or a finger near a suspected leak. Inspect for high-pressure fuel leaks with a sheet of cardboard (2) (typical picture). High fuel injection pressure can cause personal injury if contact is made with the skin. Start the engine. Move the cardboard (2) over the suspected high-pressure fuel line leak, and check for fuel spray onto the cardboard. If line is leaking, retorque line while engine is shutdown. Replace damaged, restricted or leaking high-pressure fuel lines with the correct replacement line. CAUTION: The high-pressure fuel lines must be clamped securely in place in the brace. The lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. Only use the recommended lines when replacement of high-pressure fuel line is necessary. NOISE ISOLATORS Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Removal Fuel Supply Line: Service and Repair Removal REMOVAL CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. If removing fuel line at either No. 1 or No. 2 cylinder, the air inlet housing/EGR valve assembly must first be removed from the top of the intake manifold. 1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables. 2. Thoroughly clean fuel lines at both ends. CAUTION: When loosening or tightening high-pressure lines attached to a separate fitting (11), use a back-up wrench on fitting (12). Do not allow fittings (12) to rotate. Damage to both fuel line and fitting will result. 3. If removing fuel line at # 6 cylinder, a bracket (4) is located above fuel line connection at cylinder head. Two bolts (3) secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these two bracket bolts. Tilt bracket down to gain access to # 6 fuel line connection. 4. If removing fuel line at either #1 or #2 cylinder, the air inlet housing/EGR assembly must first be removed from top of intake manifold. 5. Place shop towels around fuel lines at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine. 6. Carefully remove each fuel line from engine. Note position of each while removing. Do not bend lines while removing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Removal > Page 6509 Fuel Supply Line: Service and Repair Installation INSTALLATION All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation. CAUTION: Anytime a high-pressure line is removed from the engine, its fuel connector nut (12) at the cylinder head must first be retorqued. 1. Tighten nuts (12) at high pressure injector connector nut at the cylinder head. Torque nut to 50 Nm (37 ft. lbs.). 2. Position proper fuel line to proper injector on engine. Tighten fittings hand tight at both ends of line. 3. Tighten fuel line at cylinder head. Torque nut to 40 Nm (30 ft. lbs.). 4. Tighten fuel line nuts at fuel rail to 40 Nm (30 ft. lbs.). 5. If fuel line at No. 6 cylinder has been replaced, tilt metal bracket (4) upward and tighten two bolts (3) at rear of cylinder head. Tighten to 43 Nm (32 ft. lbs.). 6. If necessary, install EGR valve/air intake manifold assembly. 7. Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components. 8. Connect both negative battery cables to both batteries. 9. Prime fuel system. 10. Check lines/fittings for leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair REMOVAL/INSTALLATION For diesel removal and installation procedures, See Fuel Level Sending Unit/Sensor Removal/Installation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit Fuel Tank Vent: Technical Service Bulletins Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit NUMBER: 14-004-11 GROUP: Fuel System DATE: April 01, 2011 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-002-10, DATED FEBRUARY 11, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE NEW PARTS. SUBJECT: Heavy Duty Filtration MOPAR Retrofit or Add On Parts Available MODELS: 2003 - 2009 (D1/DH/DR) Ram Truck (2500/3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Cab Chassis) NOTE: This bulletin applies to D1/DH/DR vehicles equipped with a 5.9L Cummins engine built from 2003 model year (sales codes ETH, ETC) and DC/DH/D1/vehicles equipped with a 6.7L Cummins engine built from 2007 model year (sales code ETJ). DISCUSSION: Several fuel system add-on or retrofit parts are available to enhance the filtering capability for customers exposing their vehicles to extremely dirty conditions. Description of parts available for Cummins diesel equipped vehicles are listed below: ^ **Severe duty, frame mounted fuel filter** (application for 2004.5 - 2009 Pickup & 2007 - 2010 Cab Chassis DC). ^ 6.7L up-graded (5 & 10 micron filter-in-filter) fuel filter to retrofit earlier models (shell and element). ^ 6.7L Element only, fuel filter. ^ 5.9L & 6.7L Add-on or up-graded fuel tank vent hose kit with vent cap. ^ Filter for fuel tank vent hose, (replaces vent cap). ^ 5.9L up-graded air filter. This filter is similar in design to the current 6.7L air filter. NOTE: Do not sell p/n 05183410AA fuel filter for (bottom load style) 6.7L engines. Use 68061633AA shell and filter. NOTE: The maintenance intervals for the fuel filter(s) is 15,000 miles, 400 engine hours or 12 Months, (whichever occurs first) or more often as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Fuel System - Heavy Duty MOPAR Filtration Kit Retrofit > Page 6518 PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Locations Fuel/Water Separator: Locations DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Description and Operation > Description Fuel/Water Separator: Description and Operation Description DESCRIPTION The fuel filter/water separator assembly is located on left side of engine above the starter motor. The assembly also includes the fuel heater, water drain valve, Water-In-Fuel (WIF) sensor and a quick-connect fittings attached at the side of the fuel filter canister. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Description and Operation > Description > Page 6524 Fuel/Water Separator: Description and Operation Operation OPERATION The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter. Refer to the maintenance schedules for the recommended fuel filter replacement intervals. For draining of water from canister, refer to Fuel Filter/Water Separator Removal/Installation. There is a screened quick-connect fitting that is attached at the side of the fuel filter canister. It provides additional filtering for the high pressure fuel system components. A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element. The fuel heater is installed into the side of the filter/separator housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal Fuel/Water Separator: Service and Repair Removal REMOVAL Refer to maintenance schedules, for recommended fuel filter replacement intervals. Draining water from fuel filter canister: The housing drain valve (3) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel filter or heater element replacement. The filter housing (1) should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). 1. A drain hose (4) is located at the bottom of drain valve. Place drain pan under drain hose. 2. With engine not running, rotate drain valve (3) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (3). 5. Fuel Filter Replacement: a. Remove left front tire/wheel. b. Remove left front wheel splash shield. c. Clean all debris from around filter canister (1) and canister head. d. Disconnect WIF sensor electrical connector (5). e. Open drain valve (3) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. f. Remove drain hose (4) from drain valve (3). g. Use an oil filter type wrench to loosen filter (1). Continue removing filter by hand. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6527 6. After fuel filter removal, also check and clean secondary filter screen. Press button (2) on quick-connect fitting. Disconnect fitting (1) from fitting (3). Unscrew fitting (3) from canister head to expose screen. 7. Clean screen (5) and check condition of O-ring (6). 8. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor (2) is located on the bottom of the fuel filter housing. The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly (1) needs to be changed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6528 9. Fuel Heater Element Replacement: The heater element (2) is located in the fuel filter housing (4). a. Drain fuel filter. See previous steps. b. Disconnect electrical connector (1). c. Remove two mounting screws (3). d. Remove fuel heater (2). 10. Check condition of fuel heater O-ring (2). 11. Drain Valve Replacement: The Drain Valve is located on the bottom of the fuel filter. This is not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister assembly. 12. Fuel Filter Head (Housing) Replacement: a. If equipped, remove transmission dipstick tube from filter housing. b. Remove all low-pressure fuel lines at filter housing c. Remove housing from cylinder head. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6529 Fuel/Water Separator: Service and Repair Installation INSTALLATION Refer to maintenance schedules for recommended fuel filter replacement intervals. 1. Fuel Filter: CAUTION: Do not pre-fill the fuel filter with fuel. Severe damage to fuel system and injection system components may result. a. The engine has a self-priming low-pressure fuel system. b. Lubricate new fuel filter O-ring with clean engine oil. c. Position new fuel filter/canister assembly (1) to housing. d. Rotate fuel filter/canister assembly (1) until it comes to a hard stop. e. Tighten the filter element an additional half-inch of rotation. f. Connect WIF sensor electrical connector (5). g. Attach drain hose (4) to drain valve (3). h. Install left front tire/wheel. i. Install left front wheel splash shield. 2. Clean screen (5). 3. Check condition of new O-ring (6) and lubricate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6530 4. Install screen assembly into housing and tighten fitting (3) to 20 ft. lbs. (27 Nm). 5. Connect quick connect fuel supply line (1) to fitting (3). 6. Fuel Heater Element: a. Check condition of O-ring (2). b. Lubricate new element O-ring before installation. 7. Install fuel heater element (3) into fuel filter housing (4). 8. Install two fuel heater mounting screws (3) and tighten to 60 in lbs. (6.8 Nm). 9. Connect electrical connector (1). 10. Fuel Filter Head (Housing): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Removal > Page 6531 a. Install fuel filter head to cylinder head. Tighten bolts to 32 Nm (24 ft. lbs.) torque. b. Replace sealing washers on banjo bolts and install all low-pressure fuel lines to filter housing. Tighten banjo bolts to 24 Nm (18 ft. lbs.) torque. Tighten quick-connect fitting to 27 Nm (20 ft. lbs.) torque. c. If equipped, install transmission dipstick tube to filter housing. Tighten bolt to 10 Nm (8 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6535 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6536 High Idle Switch: Diagrams Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6537 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Component ID 242 Intake Air Heater Relay: Locations Component ID 242 Component ID: 242 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 6543 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 6544 Intake Air Heater Relay: Locations Component ID 243 Component ID: 243 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 6545 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 Intake Air Heater Relay: Diagrams Component ID 242 Component ID: 242 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 6548 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 6549 Intake Air Heater Relay: Diagrams Component ID 243 Component ID: 243 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 6550 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Diagrams > Page 6551 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 6554 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6558 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6559 Main Relay (Computer/Fuel System): Diagrams Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6560 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6561 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6562 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 Fuel Pump Relay: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 6586 Fuel Pump Relay: Description and Operation The fuel transfer pump (fuel lift pump) is part of the fuel pump module. The fuel pump module is located in the fuel tank. The 12-volt electric pump is operated and controlled by the Engine Control Module (ECM). The ECM controls a relay in the intelligent Power Module (IPM) for transfer pump operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 Intake Air Heater Relay: Locations Component ID 242 Component ID: 242 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 6591 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 6592 Intake Air Heater Relay: Locations Component ID 243 Component ID: 243 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Component ID 242 > Page 6593 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 Intake Air Heater Relay: Diagrams Component ID 242 Component ID: 242 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 6596 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 6597 Intake Air Heater Relay: Diagrams Component ID 243 Component ID: 243 Component : RELAY-INTAKE AIR HEATER Connector: Name : RELAY-INTAKE AIR HEATER Color : # of pins : 5 Qualifier : (DIESEL) 30 A19 10DG FUSED B(+) 30 A19 10RD/YL FUSED B(+) 85 K174 18BR/YL INTAKE AIR HEATER RELAY CONTROL 86 Z174 18BK GROUND 86 K974 18BR/BK INTAKE AIR HEATER RELAY CONTROL RETURN 87 A58 4BK INTAKE AIR HEATER RELAY OUTPUT Component Location - 4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Component ID 242 > Page 6598 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Diagrams > Page 6599 Intake Air Heater Relay: Description and Operation OPERATION The Engine Control Module (ECM) operates the heating element through the intake manifold air heater relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal Intake Air Heater Relay: Service and Repair Removal REMOVAL The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect relay trigger wires (4) at relays. Note position of wiring before removing. 3. Remove nuts (2) at cable connectors and disconnect cables (1) from mounting studs. Note position of cables before removing. 4. Remove two relay mounting bracket screws (6) and remove relay assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Service and Repair > Removal > Page 6602 Intake Air Heater Relay: Service and Repair Installation INSTALLATION The intake manifold air heater relay (5) is located in the engine compartment. It attached to a bracket. This bracket is attached to the right battery tray (3). The mounting bracket and relay is replaced as an assembly. 1. Position relay and install two relay mounting bracket screws (6). 2. Position cables (1) to mounting studs and install nuts (2). 3. Connect relay trigger wires (4) at relays. 4. Connect both negative battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6606 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6607 Main Relay (Computer/Fuel System): Diagrams Component ID: 244 Component : RELAY-SMART POWER Connector: Name : RELAY-SMART POWER Color : # of pins : 5 Qualifier : (6.7L DIESEL) Pin Circuit Description 1 A118 18RD/OR FUSED B(+) 2 A118 18RD/OR FUSED B(+) 3-4 F348 16PK/OR SMART POWER RELAY FEED 5 K348 18BR SMART POWER RELAY RETURN Component Location - 33 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6608 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6609 Main Relay (Computer/Fuel System): Testing and Inspection Fig.1 ASD And Fuel Pump Relay Terminals-Type 1 Fig.2 ASD And Fuel Pump Relay Terminals-Type 2 The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, or. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. In the OFF position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 6610 ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6615 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6616 Accelerator Pedal Position Sensor: Diagrams Component ID: 401 Component : SENSOR-ACCELERATOR PEDAL POSITION Connector: Name : SENSOR-ACCELERATOR PEDAL POSITION Color : BLACK # of pins : 6 Pin Circuit Description 1 F855 20PK/YL 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/LB 5 VOLT SUPPLY Pin Circuit Description 1 K852 20BR/VT 5 VOLT SUPPLY 2 K23 20BR/WT APPS NO. 1 SIGNAL 3 K167 20BR/YL APPS NO. 1 RETURN 3 K167 20BR/DG APPS NO. 1 RETURN 4 K400 20BR/VT APPS NO. 2 RETURN 5 K29 20WT/BR APPS NO. 2 SIGNAL 6 F856 20YL/PK 5 VOLT SUPPLY 6 K854 20VT/BR 5 VOLT SUPPLY Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 6617 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 6620 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) provides the Engine Control Module (ECM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal Accelerator Pedal Position Sensor: Service and Repair Removal REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6-way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal > Page 6623 Accelerator Pedal Position Sensor: Service and Repair Installation INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6-way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC's). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6627 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6628 Air Flow Meter/Sensor: Diagrams Component ID: 427 Component : SENSOR-MASS AIR FLOW Connector: Name : SENSOR-MASS AIR FLOW Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 K157 18BR/OR MASS AIR FLOW SENSOR SIGNAL 2 F348 16PK/OR SMART POWER RELAY FEED 3 K916 18BR/OR SENSOR GROUND 4-Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6629 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 6630 Air Flow Meter/Sensor: Description and Operation OPERATION The Mass Airflow (MAF) sensor is a frequency based device. A constant voltage is applied to a heated wire on the sensor. This wire is positioned in the air cleaner air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a positive temperature coefficient resistor. This means that its resistance drops when its temperature drops. The drop in resistance allows more current to flow through it in order to maintain the programmed temperature. This current is changed to a frequency which is sent to the Engine Control Module (ECM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration because they also affect the temperature of the heated wire or film. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal Air Flow Meter/Sensor: Service and Repair Removal REMOVAL The Mass Airflow Sensor (5) is located on the air cleaner cover (8). 1. Disconnect electrical connector (6) at sensor. 2. Remove two mounting screws (4). 3. Remove sensor from air cleaner cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Service and Repair > Removal > Page 6633 Air Flow Meter/Sensor: Service and Repair Installation INSTALLATION 1. Check condition of sensor O-ring. 2. Position sensor into top of air cleaner cover with a slight twisting action. 3. Install mounting screw (4). 4. Install electrical connector (6). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations Component ID: 419 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 K915 18BR/WT FUEL RAIL SENSOR RETURN Pin Circuit Description 1 K916 18BR/OR SENSOR GROUND 2 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 3 F855 18PK/YL 5 VOLT SUPPLY Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6637 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6638 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6639 Fuel Pressure Sensor/Switch: Diagrams Component ID: 419 Component : SENSOR-FUEL RAIL PRESSURE Connector: Name : SENSOR-FUEL RAIL PRESSURE Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 K915 18BR/WT FUEL RAIL SENSOR RETURN Pin Circuit Description 1 K916 18BR/OR SENSOR GROUND 2 K181 18BR/YL FUEL RAIL SENSOR SIGNAL 3 F855 18PK/YL 5 VOLT SUPPLY Component Location - 18 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6640 Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6641 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 6642 Fuel Pressure Sensor/Switch: Description and Operation OPERATION The fuel pressure sensor monitors actual high-pressure within the fuel rail. An output signal from this sensor (relating to fuel pressure) is sent to the Engine Control Module (ECM). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal Fuel Pressure Sensor/Switch: Service and Repair Removal REMOVAL The fuel pressure sensor (1) is mounted to the rear of the fuel rail (6). 1. Remove two bolts (3) and bracket (4) at rear of cylinder head. 2. Remove engine oil dipstick tube mounting bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 6645 3. Disconnect electrical connector (2) at sensor. 4. Remove sensor (1) from fuel rail. 5. Inspect sensor sealing surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Removal > Page 6646 Fuel Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect fuel pressure sensor sealing surface. 2. Lubricate sensor threads with clean diesel fuel. 3. Install sensor (1) into fuel rail. 4. To prevent leaks, sensor must be tightened to 70 Nm (52 ft. lbs.). 5. Connect electrical connector (2) to sensor. 6. Install rear engine lift bracket (4) and bolts (3). Tighten to 77 Nm (57 ft. lbs.). 7. Install engine oil dipstick tube mounting bolts. Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components. 8. Start engine and check for fuel leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations High Idle Switch: Locations Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6650 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6651 High Idle Switch: Diagrams Component ID: 212 Component : MODULE-REMOTE THROTTLE PROVISION Connector: Name : MODULE-REMOTE THROTTLE PROVISION Color : # of pins : 10 Qualifier : (6.7L DIESEL) Gender : FEMALE Pin Circuit Description 1 K854 18VT/BR 5 VOLT SUPPLY 2 K400 18BR/VT APPS NO. 2 RETURN 3 K128 18DB/LG REMOTE THROTTLE SIGNAL 4 K129 18DB/DG REMOTE THROTTLE SWITCH SIGNAL 5 K119 18LG/BK MAXIMUM OPERATING SPEED SWITCH SIGNAL 6 K810 18VT/DG ACCELERATOR INTERLOCK SWITCH SIGNAL 7 F425 18PK REMOTE POWER TAKEOFF SWITCH RELAY SIGNAL 8 V937 18VT/BR S/C SWITCH RETURN 9 K425 18OR/BR IN CAB POWER TAKEOFF SWITCH INPUT 10 - Component Location - 14 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Locations > Page 6652 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Component ID: 446 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 2 K541 18BR/VT TURBO SPEED SENSOR GROUND Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 6656 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 6657 Turbo Boost Sensor: Diagrams Component ID: 446 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 2 K541 18BR/VT TURBO SPEED SENSOR GROUND Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Locations > Page 6658 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal Turbo Boost Sensor: Service and Repair Removal REMOVAL CAUTION: Do not use a screw driver or tool to pry sensor out of the turbocharger bearing housing. Damage to sensor may result. If sensor is damaged during removal, install a new sensor. 1. Disconnect negative battery cable. 2. Remove turbocharger oil supply line. 3. Disconnect speed sensor electrical connector. 4. Remove turbocharger speed sensor mounting bolt (1). 5. Remove turbocharger speed sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbo Boost Sensor > Component Information > Service and Repair > Removal > Page 6661 Turbo Boost Sensor: Service and Repair Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). 4. Connect speed sensor electrical connector. 5. Install turbocharger oil supply line. Tighten fitting to 24 Nm (18 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Description and Operation > Description Intercooler: Description and Operation Description DESCRIPTION The charge air system consists of the charge air cooler piping, charge air cooler and intake air grid heater. The Charge Air Cooler is a heat exchanger that uses air flow from vehicle motion to dissipate heat from the intake air. As the turbocharger increases air pressure, the air temperature increases. Lowering the intake air temperature increases engine efficiency and power. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Description and Operation > Description > Page 6667 Intercooler: Description and Operation Operation OPERATION Intake air is drawn through the air cleaner and into the turbocharger compressor housing. Pressurized air from the turbocharger then flows forward through the charge air cooler located in front of the radiator. From the charge air cooler the air flows back into the intake manifold. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Diagnosis and Testing Intercooler: Service and Repair Diagnosis and Testing LEAKS Low turbocharger boost pressure and low engine performance can be caused by leaks in the charge air cooler or plumbing. Fuel staining on the exhaust manifold can also be an indication that there are leaks in the air system. The following procedure outlines how to check for leaks in the charge air cooler system. This procedure can also be used to check for leaks in the wastegate signal line or the wastegate canister. 1. Loosen clamp and remove air inlet hose from turbocharger. 2. Insert Special Tool 9022 Adapter and tool 9861 into the turbocharger inlet. Tighten tool clamp to 8 Nm (72 in. lbs.). CAUTION: Do not apply more than 138 kPa (20 psi) air pressure to the charge air cooler system, severe damage to the charge air cooler system may occur. 3. Connect a regulated air supply to air fitting on Tool 9022 Adapter. Apply 27.5 - 55 kPa (4 - 8 psi) to Tool 9861. 4. Using soapy water check the rubber sleeves, clamps, charge air cooler and intake manifold for leaks. 5. Using soapy water check for leaks at the wastegate signal line, wastegate canister and wastegate command valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Diagnosis and Testing > Page 6670 Intercooler: Service and Repair Removal REMOVAL WARNING: IF THE ENGINE WAS JUST TURNED OFF, THE AIR INTAKE SYSTEM TUBES MAY BE HOT. 1. Disconnect the battery negative cables. 2. Discharge the A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery and remove the A/C condenser See: Heating and Air Conditioning/Condenser HVAC/Service and Repair/A/C Condenser Removal (if A/C equipped). 3. Remove the transmission auxiliary cooler See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Cooler/Service and Repair/Removal and Replacement/Transmission Oil Cooler - Removal . 4. Remove intake air tubing from the charge air cooler. 5. Remove the charge air cooler bolts. Pivot the charge air cooler forward and up to remove. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Diagnosis and Testing > Page 6671 Intercooler: Service and Repair Cleaning CLEANING CAUTION: Do not use caustic or acid based cleaners to clean the charge air cooler. Damage to the charge air cooler will result. NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced. NOTE: Charge air cooler must be a room temperature for this procedure. 1. If the engine experiences a turbocharger failure or any other situation where oil or debris get into the charge air cooler, the charge air cooler must be cleaned internally. 2. Remove charge air cooler See: Removal 3. Position the charge air cooler so the inlet and outlet tubes are vertical. 4. Flush the cooler internally with solvent such as mineral spirits in the direction opposite of normal air flow. 5. Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. 6. Continue flushing until all debris or oil are removed. 7. Rinse the cooler with hot soapy water to remove any remaining solvent. 8. Rinse thoroughly with clean water and blow dry with compressed air. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Diagnosis and Testing > Page 6672 Intercooler: Service and Repair Inspection INSPECTION Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. Replace the charge air cooler if damage is found. Pressure test the charge air cooler using Charge Air Cooler Tester Kit No. 3824556. This kit is available through Cummins(R) Service Products. Instructions are provided with the kit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Service and Repair > Diagnosis and Testing > Page 6673 Intercooler: Service and Repair Installation INSTALLATION 1. Position the charge air cooler. Install the bolts and tighten to 2 Nm (17 in. lbs.) torque. 2. Install the air intake system tubes to the charge air cooler. With the clamps in position, tighten the clamps to 11 Nm (95 in. lbs.) torque. 3. Install the transmission auxiliary cooler (if equipped) See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Transmission Cooler/Service and Repair/Removal and Replacement/Transmission Oil Cooler - Installation . 4. Install the A/C condenser (if A/C equipped) See: Heating and Air Conditioning/Condenser HVAC/Service and Repair/A/C Condenser Installation . Recharge A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge . 5. Connect the battery negative cables. 6. Start engine and check for boost system leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations Turbo Boost Sensor: Locations Component ID: 446 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 2 K541 18BR/VT TURBO SPEED SENSOR GROUND Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Page 6677 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Page 6678 Turbo Boost Sensor: Diagrams Component ID: 446 Component : SENSOR-TURBO SPEED Connector: Name : SENSOR-TURBO SPEED Color : # of pins : 2 Qualifier : (6.7L) Pin Circuit Description 1 K540 18BR/GY TURBO SPEED SENSOR SIGNAL 2 K541 18BR/VT TURBO SPEED SENSOR GROUND Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Locations > Page 6679 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Removal Turbo Boost Sensor: Service and Repair Removal REMOVAL CAUTION: Do not use a screw driver or tool to pry sensor out of the turbocharger bearing housing. Damage to sensor may result. If sensor is damaged during removal, install a new sensor. 1. Disconnect negative battery cable. 2. Remove turbocharger oil supply line. 3. Disconnect speed sensor electrical connector. 4. Remove turbocharger speed sensor mounting bolt (1). 5. Remove turbocharger speed sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Sensor > Component Information > Service and Repair > Removal > Page 6682 Turbo Boost Sensor: Service and Repair Installation INSTALLATION 1. Install turbocharger speed sensor. 2. Install turbocharger speed sensor mounting bolt. 3. Tighten bolt to 10 Nm (89 in. lbs.). 4. Connect speed sensor electrical connector. 5. Install turbocharger oil supply line. Tighten fitting to 24 Nm (18 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Locations Wastegate Actuator: Locations Component ID: 3 Component : ACTUATOR-ELECTRONIC TURBO Connector: Name : ACTUATOR-ELECTRONIC TURBO Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 F348 16PK/OR SMART POWER RELAY FEED 2 K972 18DB/TN ACTUATOR GROUND 3 D130 18BR/VT ACTUATOR HIGH DATA LINK 4 D131 18WT/LG ACTUATOR LOW DATA LINK Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Locations > Page 6686 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Locations > Page 6687 Wastegate Actuator: Diagrams Component ID: 3 Component : ACTUATOR-ELECTRONIC TURBO Connector: Name : ACTUATOR-ELECTRONIC TURBO Color : # of pins : 4 Qualifier : (6.7L) Pin Circuit Description 1 F348 16PK/OR SMART POWER RELAY FEED 2 K972 18DB/TN ACTUATOR GROUND 3 D130 18BR/VT ACTUATOR HIGH DATA LINK 4 D131 18WT/LG ACTUATOR LOW DATA LINK Component Location - 16 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Locations > Page 6688 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Locations > Page 6689 Wastegate Actuator: Description and Operation DESCRIPTION ELECTRONICALLY CONTROLLED ACTUATOR The Electronically Controlled Actuator is mounted to the turbocharger bearing housing. The actuator consists of an integrated controller and a gear train that controls the position of the sliding nozzle ring. The actuator uses a signal from the Engine Control Module (ECM) to control the relationship between the sliding nozzle ring and turbine blades. Moving the nozzle ring rearward or forward redirects the exhaust flow so that the turbine wheel spins faster or slower as needed - If the sliding nozzle is moved rearward, the turbocharger builds more pressure (turbine wheel moves faster) - If the sliding nozzle is moved forward, the turbocharger builds less pressure (turbine wheel moves slower) VGT EXHAUST BRAKE The VGT Exhaust Brake works in conjunction with the engine and transmission to provide an integrated braking system to help slow the vehicle. This is commonly referred to as exhaust braking. Braking power is achieved by modulating the sliding nozzle ring to restrict the flow of exhaust gasses from the engine, this will create high back pressure on the engine. The high back pressure creates a high level of resistance to the motion of the pistons within the engine and this resistance is used to reduce engine speed and thus vehicle. The exhaust brake feature will only function when the Exhaust Brake Switch to the ON position. With the switch in the ON Position and the vehicle moving faster then 5 MPH; the exhaust brake will automatically operate when pressure is removed from the accelerator pedal allowing the ECM to see 0% throttle and 0% fuel delivery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Service and Repair > Removal Wastegate Actuator: Service and Repair Removal REMOVAL 1. Disconnect the battery negative cables. 2. Raise vehicle on hoist. 3. Drain cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 4. Remove air filter housing See: Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Removal . 5. Disconnect turbocharger actuator electrical connector (1). 6. Remove turbocharger actuator mounting bolts (3). 7. Remove turbocharger actuator (2). 8. Clean mounting surface. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Service and Repair > Removal > Page 6692 Wastegate Actuator: Service and Repair Installation INSTALLATION 1. Clean turbocharger actuator housing and turbocharger mounting surfaces. 2. Position turbocharger actuator in engine compartment so gear will be free to rotate. 3. Connect turbocharger actuator electrical connector. 4. Connect negative battery cable. 5. Using a scan tool function "MISC FCN" under ECU, perform TURBO ACTUATOR PRE-ALIGN. NOTE: Do not turn key OFF after performing TURBO ACTUATOR PRE-ALIGN procedure. This holds the actuator gear in position for installation. CAUTION: Use only turbocharger actuator grease supplied in the service kit. Use of any other type of grease or too much grease may result in damage to turbocharger. Use the full amount of grease supplied with the service kit. 6. Apply grease to turbocharger actuator sector gear in a line across center of all teeth. 7. Install O-ring on turbocharger actuator. 8. If necessary, rotate sector gear clockwise (rearward) and insert small end of alignment tool (or 0.125 in. pin or a 1/8 in drill.) through sector gear until it engages the alignment hole in turbocharger bearing housing and sector gear will not rotate. If alignment pin does not engage hole in turbocharger bearing housing, variable geometry mechanism is not opening completely, refer to See: Testing and Inspection/Variable Geometry Mechanism Checks . 9. Install guide pins on turbocharger. 10. Remove alignment pin from turbocharger actuator sector gear. Turbocharger actuator sector gear must stay in this position, rotated fully clockwise while installing actuator. 11. Position turbocharger actuator on guide pins and install. 12. Install two mounting screws. Hand tighten only. 13. Remove guide pins. Install remaining two mounting screws. Tighten mounting screws in a cross pattern to 11 Nm (96 in. lbs.). 14. Using scan tool, perform TURBO ACTUATOR SELF CALIBRATE procedure. NOTE: If the TURBO ACTUATOR SELF CALIBRATE procedure fails, remove actuator and repeat installation one additional time. If this fails to clear error, replace turbocharger. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Actuator > Component Information > Service and Repair > Removal > Page 6693 15. Place ignition in the OFF position. 16. Install air filter housing See: Air Cleaner Housing/Service and Repair/Air Cleaner Housing - Installation . 17. Fill cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations Wastegate Solenoid: Locations Component ID: 463 Component : SOLENOID-WASTEGATE Connector: Name : SOLENOID-WASTEGATE Color : # of pins : 2 Qualifier : (DIESEL) A K139 18DB WASTEGATE SOLENOID CONTROL B A212 18PK/YL FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations > Page 6697 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations > Page 6698 Wastegate Solenoid: Diagrams Component ID: 463 Component : SOLENOID-WASTEGATE Connector: Name : SOLENOID-WASTEGATE Color : # of pins : 2 Qualifier : (DIESEL) A K139 18DB WASTEGATE SOLENOID CONTROL B A212 18PK/YL FUSED B(+) Component Location - 12 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate Solenoid > Component Information > Locations > Page 6699 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications DESCRIPTION The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal ribs for superior strength and noise reduction. The block incorporates metric straight thread O-ring fittings at lubrication oil access points. The engine is manufactured with the cylinders being a non-sleeved type cylinder. The cylinders are numbered front to rear ; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6707 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6708 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6709 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6710 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6711 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6712 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6713 Camshaft Position Sensor: Diagrams Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6714 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6715 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6716 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6717 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6718 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6719 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 6722 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor o-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 6725 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor o-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 6730 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) for the CKP is located behind the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 6733 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6738 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6739 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6740 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6741 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6742 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6743 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6744 Camshaft Position Sensor: Diagrams Component ID: 405 Component : SENSOR-CAMSHAFT POSITION Connector: Name : SENSOR-CAMSHAFT POSITION Color : # of pins : 3 Qualifier : (DIESEL) Pin Circuit Description 1 F855 18PK/YL 5 VOLT SUPPLY 2 K944 18BK/GY CMP SENSOR GROUND 2 K916 18BR/OR SENSOR GROUND 3 K44 18DB/GY CMP SIGNAL Component Location - 5 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6745 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6746 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6747 Connector: Name : SENSOR-CAMSHAFT POSITION Color : GRAY # of pins : 3 Qualifier : (GAS) Pin Circuit Description 1 F856 20YL/PK 5 VOLT SUPPLY 2 K900 20DB/DG SENSOR GROUND 3 K44 20DB/GY CMP SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6748 Component Location - 5 Component Location - 11 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6749 Component Location - 13 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6750 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description Camshaft Position Sensor: Description and Operation Description 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) is located below the fuel injection pump. It is bolted to the back of the timing gear cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 6753 Camshaft Position Sensor: Description and Operation Operation 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) (1) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CMP. When the leading edge of the tonewheel notch passes the tip of the CMP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CMP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses the CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. The Crankshaft Position Sensor (CKP) is the primary engine speed indicator for the engine after the engine is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.9L/6.7L DIESEL The Camshaft Position Sensor (CMP) on the diesel engine is located below the fuel injection pump (1). It is bolted to the back of the timing gear cover. 1. Disconnect electrical connector (5) at CMP sensor. 2. Remove sensor mounting bolt (6). 3. Carefully twist sensor from timing gear cover. 4. Check condition of sensor o-ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 6756 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.9L/6.7L DIESEL The CMP (1) is located on the back of the timing gear cover. 1. Clean out machined hole in back of timing gear cover. 2. Apply a small amount of engine oil to sensor o-ring. 3. Install sensor into timing gear cover with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to back of timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 4. Install mounting bolt and tighten to 12 Nm (106 in.lbs.). 5. Connect electrical connector to sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The Crankshaft Position Sensor (CKP) on the diesel engine is attached at the front / left side of the engine next to the engine harmonic balancer (crankshaft damper). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 6761 Crankshaft Position Sensor: Description and Operation Operation OPERATION The Crankshaft Position Sensor (CKP) (5) is the primary engine speed indicator for the engine after the engine is running. The CKP contains a hall effect device. A rotating, notched target wheel (tonewheel) for the CKP is located behind the engine harmonic balancer (2). This hall effect device detects notches located on the tonewheel. As the tonewheel rotates, the notches pass the tip of the CKP. When the leading edge of the tonewheel notch passes the tip of the CKP, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a signal of approximately 5 volts. When the trailing edge of the tonewheel notch passes the tip of the CKP, the following occurs: The change of the magnetic field causes the signal voltage to switch low to 0 volts. The Camshaft Position Sensor (CMP) also provides a signal to the Engine Control Module (ECM) at all times when the engine is running. The ECM uses this CMP information primarily on engine start-up. Once the engine is running, the ECM uses the CMP as a backup sensor for engine speed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL 1. Raise and support vehicle 2. Disconnect electrical connector (4) at CKP sensor. 3. Remove 1 sensor mounting bolt (3). 4. Remove CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 6764 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Position and install CKP sensor (5) to engine. 2. Install 1 sensor mounting bolt and tighten to 9 Nm (80 in. lbs.) torque. 3. Install electrical connector (4) to CKP sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal Ignition Switch Lock Cylinder: Service and Repair Removal REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal > Page 6770 Ignition Switch Lock Cylinder: Service and Repair Installation INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Description and Operation > Description Wait To Start Light: Description and Operation Description DESCRIPTION A wait-to-start indicator is only found in the instrument clusters for vehicles equipped with an optional diesel engine. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The wait-to-start indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Diesel Preheat in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The wait-to-start indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Description and Operation > Description > Page 6776 Wait To Start Light: Description and Operation Operation OPERATION The wait-to-start indicator gives an indication to the vehicle operator when the air temperature within the diesel engine intake manifold is too cool for efficient and reliable engine starting, and that the intake air heater grids are energized in their pre-heat operating mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Engine Control Module (ECM) over the Controller Area Network (CAN) data bus. The wait-to-start indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the wait-to-start indicator for the following reasons: - Wait-To-Start Indicator Lamp-On Message - Each time the cluster receives an electronic wait-to-start indicator lamp-ON message from the ECM indicating that the air temperature within the intake manifold is too cool for efficient and reliable engine starting, the wait-to-start indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message, until the ECM detects that the engine is running or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the wait-to-start indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The ECM continually monitors the engine intake air temperature sensor to determine when the intake air heater grids should be energized in their pre-heat operating mode. The ECM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the wait-to-start indicator or the instrument cluster circuitry that controls the indicator, Refer to appropriate testing. For proper diagnosis of the engine intake air temperature sensor, the intake air heater grid control circuits, the ECM, the EMIC, the CAN data bus or the electronic communication related to wait-to-start indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 6784 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 6787 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6792 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6793 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6794 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6795 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6796 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6797 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6798 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6799 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6800 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6801 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6802 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6803 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6804 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6805 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6808 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6809 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6810 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6811 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6812 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6813 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6814 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6815 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6816 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6817 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6818 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6819 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6820 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6821 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 6824 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 6827 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 455 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Circuit Description 1 K32 18DB/YL BTSI SOLENOID CONTROL 2 Z101 18BK/VT GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6831 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6832 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6833 Shift Interlock Solenoid: Diagrams Component ID: 455 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Circuit Description 1 K32 18DB/YL BTSI SOLENOID CONTROL 2 Z101 18BK/VT GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6834 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 6835 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6840 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6841 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6842 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6843 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6844 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6845 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6846 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6847 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6848 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6849 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6850 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6851 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6852 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 20 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T60 20YL/GY OD CONTROL 2 T59 20YL/LB UD CONTROL 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 4 T19 18YL/DB 2-4 CONTROL 5 T47 18YL/DG 2-4 PRESSURE SIGNAL 6 T9 20DG/TN OD PRESSURE SIGNAL 7 T20 20DG/WT L/R CONTROL 8-9-10 T50 20YL/TN L/R PRESSURE SIGNAL Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6853 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6854 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 6855 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6858 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6859 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6860 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6861 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6862 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6863 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6864 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6865 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6866 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6867 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6868 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6869 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6870 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 6871 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 6874 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 6877 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 6881 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 6884 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA See: Adjustments . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 6890 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 6891 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 202 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Circuit Description 1 Z906 20BK GROUND 2 G304 20VT/DB FRONT AXLE LOCK CONTROL 3 A880 20DB/RD FUSED B(+) 4 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 6896 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 6897 Solenoid: Locations Solenoid-Locker-Front Component ID: 457 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T520 16YL/OR FRONT LOCKER SOURCE 2 T521 18YL/BK LOCKER SENSOR SUPPLY 3 T522 18YL/LB FRONT LOCKER SENSOR SENSE 4 T524 16YL/LG FRONT LOCKER RETURN Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 6898 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 6899 Solenoid: Locations Solenoid-Locker-Rear Component ID: 458 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T526 16YL/WT REAR LOCKER SOURCE 2 T523 18YL/BK LOCKER SENSOR SUPPLY 3 T527 18YL/TN REAR LOCKER SENSOR SENSE 4 T528 16YL/GY REAR LOCKER RETURN Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 6900 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 202 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Circuit Description 1 Z906 20BK GROUND 2 G304 20VT/DB FRONT AXLE LOCK CONTROL 3 A880 20DB/RD FUSED B(+) 4 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 6903 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 6904 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 457 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T520 16YL/OR FRONT LOCKER SOURCE 2 T521 18YL/BK LOCKER SENSOR SUPPLY 3 T522 18YL/LB FRONT LOCKER SENSOR SENSE 4 T524 16YL/LG FRONT LOCKER RETURN Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 6905 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 6906 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 458 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T526 16YL/WT REAR LOCKER SOURCE 2 T523 18YL/BK LOCKER SENSOR SUPPLY 3 T527 18YL/TN REAR LOCKER SENSOR SENSE 4 T528 16YL/GY REAR LOCKER RETURN Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 6907 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 6912 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 6913 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 6914 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 6915 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 6916 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 6917 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 Transfer Case Actuator: Diagrams Component ID 14 Component ID: 14 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 6920 Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 6921 Transfer Case Actuator: Diagrams Component ID 18 Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 6922 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 6923 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 6924 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 6925 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 6926 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 6927 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (2) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (2) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 6930 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (2) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 6931 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 6932 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (2) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts (3) holding the shift motor and mode sensor assembly (2) onto the transfer case (1). 4. Separate the shift motor and mode sensor assembly (2) from the transfer case. Installation INSTALLATION 1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly (2) onto the transfer case (1). 3. Install the bolts (3) to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 6935 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts (3) holding the shift motor and mode sensor assembly (2) onto the transfer case (1). 4. Separate the shift motor and mode sensor assembly (2) from the transfer case. Installation INSTALLATION 1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly (2) onto the transfer case (1). 3. Install the bolts (3) to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 6936 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 6937 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 6938 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 3. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) onto the transfer case. Tighten the bolts to 23.5 Nm (17 ft.lbs.). 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the front propeller shaft. See: Transmission and Drivetrain/Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement 6. Refill the transfer case as necessary with the correct fluid for the application. 7. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 6939 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts (3) holding the shift motor and mode sensor assembly (2) onto the transfer case (1). 4. Separate the shift motor and mode sensor assembly (2) from the transfer case. Installation INSTALLATION 1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly (2) onto the transfer case (1). 3. Install the bolts (3) to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Description Overdrive Indicator Lamp: Description and Operation Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Description > Page 6946 Overdrive Indicator Lamp: Description and Operation Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, Refer to appropriate testing. For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 6951 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation > Description Transmission Mode Indicator - A/T: Description and Operation Description DESCRIPTION An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Each character appears in a blue-green color and at the same lighting level as the odometer information. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps are OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster general illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a PARADE mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation > Description > Page 6956 Transmission Mode Indicator - A/T: Description and Operation Operation OPERATION The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission type that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon an electronic selected gear message received from the Transmission Control Module (TCM) over the Controller Area Network (CAN) data bus. If the Transmission Range Sensor (TRS) mux circuit is open and no electronic selected gear messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the TRS. If the cluster is configured for an automatic transmission with a TRS input and detects a short to ground or an open in the TRS mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the TRS, then sends the proper message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles without a TCM, the EMIC continually monitors the hard wired TRS multiplexed input. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the EMIC, the CAN data bus or the electronic communication related to gear selector indicator operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 6962 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4 Low Indicator 4 LOW INDICATOR A 4 low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4 low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4 low indicator consists of a stencil-like cutout of the text 4 LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4 low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4 low indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 6963 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4 Low Indicator 4 LOW INDICATOR The 4 low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 6964 the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4 low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4 low indicator for the following reasons: - 4 Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4 low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4 low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the 4 low indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4 low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 6969 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 6980 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 6981 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 6987 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 6988 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 Control Module: Locations Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 6991 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 6992 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 6993 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 6994 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 6995 Control Module: Locations Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 6996 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 6997 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 6998 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 6999 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 Control Module: Diagrams Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7002 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7003 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7004 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7005 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7006 Control Module: Diagrams Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7007 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7008 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7009 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7010 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7013 On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7014 Control Module: Description and Operation Transmission Control Module - Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7015 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7016 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7017 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7018 Some examples of TCM.indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations The Transmission Control Relay is not serviceable if equipped Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Transmission Control System Relay: Connector Views Component ID: 246 Component : RELAY-TRANSMISSION Connector: Name : RELAY-TRANSMISSION Color : # of pins : 4 Pin Circuit Description 1 A916 16RD FUSED B(+) 2 T16 16YL TRANSMISSION CONTROL OUTPUT 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 Z420 18BK GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 Control Module: Locations Component ID 197 Component ID: 197 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 7048 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 7049 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 7050 Control Module: Locations Component ID 206 Component ID: 206 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 7051 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 7052 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 Control Module: Diagrams Component ID 197 Component ID: 197 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 7055 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 7056 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 7057 Control Module: Diagrams Component ID 206 Component ID: 206 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 7058 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 7059 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location and additional information. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 7062 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ±0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ±1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ±1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ±100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 7063 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ±100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ±100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ±50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ±100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ±50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ±100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ±50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ±100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ±50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 7064 TIPM waits for 2.0 seconds ±50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ±100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TIPM will wait for 2.0 seconds ±50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 7065 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ±100 msec calibrated window of time. After 5 minutes ±100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7071 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7072 Fluid Pressure Sensor/Switch: Diagrams Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7073 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 7076 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 7079 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 7083 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 7084 Overdrive Switch: Diagrams Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 7085 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 7086 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7089 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7090 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7091 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7092 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7093 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7094 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7095 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description Shift Solenoid Position Sensor/Switch: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description > Page 7100 Shift Solenoid Position Sensor/Switch: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 545RFE PRESSURE SWITCH STATES: A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal Shift Solenoid Position Sensor/Switch: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal > Page 7103 Shift Solenoid Position Sensor/Switch: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7108 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7109 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7110 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7111 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7112 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7113 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7114 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7115 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7116 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7117 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 7118 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7121 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7122 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7123 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7124 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7125 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7126 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7127 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7128 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7129 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7130 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 7131 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7134 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7135 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7136 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 7137 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 7140 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 7141 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 7142 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 7143 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7148 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7149 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7150 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7151 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7152 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7153 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7154 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7155 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7156 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7157 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7158 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7159 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7160 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7161 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7162 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7163 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7164 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7165 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7166 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7167 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7168 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7169 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7170 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7171 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7172 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7173 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7174 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7175 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7176 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7177 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7178 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7179 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7180 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7181 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7182 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7183 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 7184 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7187 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7188 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7189 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7190 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7191 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7192 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7193 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7194 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7195 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7196 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7197 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7198 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7199 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7200 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7201 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7202 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7203 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7204 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7205 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7206 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7207 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7208 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7209 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7210 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7211 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7212 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7213 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7214 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7215 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7216 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7217 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7218 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7219 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7220 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7221 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7222 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 7223 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7226 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 7227 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7230 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7231 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7232 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7233 INPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7237 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7238 Transmission Temperature Sensor/Switch: Diagrams Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 7239 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description Transmission Temperature Sensor/Switch: Description and Operation Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 7242 Transmission Temperature Sensor/Switch: Description and Operation Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission Transmission Temperature Sensor/Switch: Service and Repair 48RE Automatic Transmission Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 7245 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 7246 Transmission Temperature Sensor/Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 7247 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 7248 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 515 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Circuit Description 1 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT 2-3 K977 20BR/WT MODE SELECT 4 E11 20OR/DB PANEL LAMPS CONTROL 5 Z905 20BK GROUND 6 G95 20VT/BR NEUTRAL INDICATOR 7 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7257 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7258 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7259 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7260 Four Wheel Drive Selector Switch: Diagrams Component ID: 515 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Circuit Description 1 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT 2-3 K977 20BR/WT MODE SELECT 4 E11 20OR/DB PANEL LAMPS CONTROL 5 Z905 20BK GROUND 6 G95 20VT/BR NEUTRAL INDICATOR 7 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7261 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7262 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 7263 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7266 - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7267 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and , T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7268 flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7269 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and , T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7270 flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7271 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 7272 - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7277 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7278 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7279 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7280 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7281 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7282 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7283 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 443 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC EXCEPT POWER WAGON) Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A 2 Z955 20BK GROUND 2 Z955 18BK GROUND 2 Z901 20BK GROUND Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7284 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7285 Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC POWER WAGON) Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7286 2 G180 18VT/YL SENSOR RETURN 2 G180 20VT/YL SENSOR RETURN Component Location - 22 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 7287 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID 14 Component ID: 14 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7290 Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component ID 18 Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7291 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7292 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7293 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7294 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7295 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7296 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7297 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 443 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC EXCEPT POWER WAGON) Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A 2 Z955 20BK GROUND 2 Z955 18BK GROUND 2 Z901 20BK GROUND Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7298 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7299 Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC POWER WAGON) Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7300 2 G180 18VT/YL SENSOR RETURN 2 G180 20VT/YL SENSOR RETURN Component Location - 22 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 7301 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7304 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7305 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7306 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Position Sensor Linear Movement During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7307 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7308 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7309 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 7310 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 7313 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the o-ring seal on the transfer case position sensor. Replace the o-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 435 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN 2 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 7318 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 7319 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 436 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T70 20YL INPUT SPEED SENSOR 1 (N2) SIGNAL 2 T341 20DG/VT INPUT SPEED SENSOR 1 (N2) RETURN Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 7320 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 435 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN 2 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 7323 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 7324 Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Rear Component ID: 436 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T70 20YL INPUT SPEED SENSOR 1 (N2) SIGNAL 2 T341 20DG/VT INPUT SPEED SENSOR 1 (N2) RETURN Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 7325 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Front Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the front output shaft speed sensor (1). 3. Remove the front output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the front output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the front output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Sensor-Output Shaft Speed-Front > Page 7328 Speed Sensor: Service and Repair Sensor-Output Shaft Speed-Rear Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connector from the rear output shaft speed sensor (1). 3. Remove the rear output shaft speed sensor from the transfer case. Installation INSTALLATION 1. Install the rear output shaft speed sensor (1) into the transfer case. Tighten the speed sensor to 17 Nm (12.5 ft.lbs.). 2. Engage the wiring connector to the rear output shaft speed sensor. 3. Lower the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7337 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7338 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7339 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7340 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7341 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7342 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7343 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7348 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7349 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7350 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7351 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7352 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7353 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7354 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 PROM - Programmable Read Only Memory: Customer Interest Computers/Controls - CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7360 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7361 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7362 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7363 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P2262 Set NUMBER: 09-002-09 GROUP: Engine DATE: May 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-001-08 and 11-002-08 BOTH DATED MAY21, 2008. THIS ISA COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: MIL Illumination Due to DIG P2262 - Revised Diagnosis and Repair Procedures OVERVIEW: This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected - Mechanical. Recent PGM calibration updates have improved the robustness to this DIG through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicle equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DTC): P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. As a result of recent PCM calibration updates, the proper repair for some P2262 faults is to just update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software update 9.05 (and later) includes a P2262 diagnosis test for this purpose. This diagnostic test uses Freeze Frame data stored in the PCM and a dynamic turbocharger response test to determine the correct repair for each truck with DTC P2262. The new P2262 diagnosis test must be used prior to performing any of the following: ^ Clearing codes. ^ Updating the PCM. ^ Beginning the turbocharger repair. The test must be used with the key in the run position with the engine off, and with coolant temperature between 50°F and 180° F. The time required to run this test will vary with the calibration level of the truck, from a few seconds up to a couple minutes. This is normal operation for the test. NOTE: The P2262 diagnosis test MUST NOT be used after the repair is complete, as this test CANNOT be used to confirm the repair. Test results will be inaccurate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7368 If the customer is experiencing MIL illumination due to Diagnostic Trouble Code (DTC): P2262 Turbocharger Boost Pressure Not Detected - Mechanical follow the revised diagnosis and repair procedures below. NOTE: Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: While the wiTECH tool is the preferred method of testing and flashing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. NOTE: Please read through this entire Service Bulletin to gain a full understanding before performing the procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTC's button. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: DO NOT erase DTC's or reprogram the PCM at this point. If P2262 is not present in the PCM due to clearing the faults or reprogramming the PCM, the P2262 diagnosis test in Scan Tool will not run. NOTE: It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC's to be erased. 5. Is DTC P2262 present in the PCM? a. If YES >> Proceed to Step # 6. b. If NO >> Then STOP. This bulletin does not apply. 6. Confirm the engine coolant temperature is between 50°F and 180°F. 7. Perform the P2262 diagnostic test with wiTECH(R), From the "Vehicle View screen select: a. Select "PCM". b. Select "Systems Tests". c. Select "P2262 Fault Diagnosis Test Start". d. Follow on-screen prompts to complete test. NOTE: If you receive an error message from test, confirm that the Diagnostic Link Connector and turbocharger actuator harness connections are secure. Also confirm that engine coolant temperature is between 50°F and 180°F, then run the test again. 8. Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Based on these results, refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info and complete Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7369 the repair as directed; a. Update PCM Flash Calibration to the latest calibration. No repair required to the turbocharger. b. Clean the Turbocharger. c. Update PCM Flash Calibration to the latest calibration and Clean the Turbocharger. d. Replace the Turbocharger. e. Update PCM Flash Calibration to the latest calibration and Replace the Turbocharger. 9. Does the vehicle have other DTC's as recorded in Step # 4 above? a. Yes >> Follow appropriate diagnosis procedures or TSB related to diagnosis and repair of each fault. b. No >> Repair complete. NOTE: All other DTC's or symptoms MUST be addressed prior to returning the vehicle to the customer. NOTE: When/if replacing Turbocharger, p/n 68048234AA or 68031095AA must NOT be used on a D1/DH (Pick Up) models. Turbocharger p/n 68048234AA or 68031095AA are to be used on DA/DC/DM (Cab/Chassis) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator PROM - Programmable Read Only Memory: Customer Interest Engine Controls - False Oil Change Indicator NUMBER: 18-005-08 REV. B GROUP: Vehicle Performance DATE: August 20, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-005-08 REV. A, DATED JUNE 13, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.05 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: FLASH: Turn Off Oil Change Indicator Message OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM). MODELS: **2008 (DR) Ram Truck (International Markets)** **2008 (HB) Durango (International Markets)** **2007 - 2008 (JK) Wrangler (International Markets)** **2007 (JK) wrangler** **2008 (KA) Nitro (International Markets)** **2008 (ND) Dakota (International Markets)** 2008 (WH) Grand Cherokee (International Markets) 2008 (XH) Commander (International Markets) NOTE: This bulletin applies to: - **2007 JK vehicles built with a 3.8L engine (sales code EGK) after June 17, 2008 (MDH 0617XX)** - **2008 JK vehicles built with a 3.8L engine (sales code EGK) before April 28, 2008 (MDH 0428XX)** - **2008 DR/HB/ND vehicles built with a 4.7L engine (sales code EVE )** - WK/WH vehicles built with a 4.7L engine (sales code EVE) built before January 25, 2008 (0125XXMDH) - KA vehicles equipped with a 4.0L engine (sales code EGS) built before July 8.2008 (MDH 0708XX) SYMPTOM/CONDITION: Some international vehicle's may experience message on the Electronic Vehicle Information Center (EVIC) or in the Odometer that tells the driver an oil change is necessary after 3000 miles. This message should not be displayed for these international vehicles and this PCM flash will turn this feature off. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If 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, perform the Repair Procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 7374 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.05 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 7375 j. Select "Update Controller". k. When the update is complete, select "OK". 7. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift PROM - Programmable Read Only Memory: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7380 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7381 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info PROM - Programmable Read Only Memory: All Technical Service Bulletins Diesel Engine Dust/Debris Ingestion/Power Upgrade Info NUMBER: 09-001-10 GROUP: Engine DATE: July 2, 2010 SUBJECT: Dust-Out Diagnosis For Cummins Diesel Engines OVERVIEW: This bulletin involves proper inspection procedures to determine engine failure due to dust-out condition. Engines damaged due to the infiltration of dirt and/or debris through the air intake system are NOT WARRANTABLE. NOTE: Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. MODELS: 2003 - 2005 (DR) Ram Pick Up Truck (2500) 2006 - 2009 (DH) Ram Pick Up Truck (2500) 2010 - 2011 (DJ) Ram Pick Up Truck (2500) 2003 - 2005 (DR) Ram Pick Up Truck (3500) 2006 - 2009 (D1) Ram Pick Up Truck (3500) 2010 - 2011 (D2) Ram Pick Up Truck (3500) 2007 - 2010 (DC) Ram Truck Cab Chassis (3500) 2011 (DD) Ram Truck Cab Chassis (3500) 2008 - 2010 (DM) Ram Truck Cab Chassis (4500/5500) 2011 (DP) Ram Truck Cab Chassis (4500/5500) NOTE: This bulletin applies to any Cummins diesel equipped vehicle still covered under the manufacturers warranty. SYMPTOM/CONDITION: Engines that exhibit particular symptoms that may have been caused by improper air filtration. Some of these symptoms are listed below (not limited to) ^ Knocking ^ Hard or no start ^ Low power / poor performance ^ Oil consumption ^ Lower end bearing failure ^ Smoking ^ Blow-by (rings not sealing) ^ Oil on turbo (dust damage to seal/bearing) NOTE: See the "Cummins Diesel Dust-Out Inspection for Warranty" document located in eFiles Under: Service> STAR Center> Cummins - HEV Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info > Page 7387 documents for pictures regarding dust-outs. NOTE: Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs. DIAGNOSIS: 1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect. 2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage. 3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles. NOTE: Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved). 6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7392 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7393 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7394 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7395 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7400 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7401 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7402 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7403 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7404 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7405 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7406 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2262 Set NUMBER: 09-002-09 GROUP: Engine DATE: May 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-001-08 and 11-002-08 BOTH DATED MAY21, 2008. THIS ISA COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: MIL Illumination Due to DIG P2262 - Revised Diagnosis and Repair Procedures OVERVIEW: This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected - Mechanical. Recent PGM calibration updates have improved the robustness to this DIG through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicle equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DTC): P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. As a result of recent PCM calibration updates, the proper repair for some P2262 faults is to just update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software update 9.05 (and later) includes a P2262 diagnosis test for this purpose. This diagnostic test uses Freeze Frame data stored in the PCM and a dynamic turbocharger response test to determine the correct repair for each truck with DTC P2262. The new P2262 diagnosis test must be used prior to performing any of the following: ^ Clearing codes. ^ Updating the PCM. ^ Beginning the turbocharger repair. The test must be used with the key in the run position with the engine off, and with coolant temperature between 50°F and 180° F. The time required to run this test will vary with the calibration level of the truck, from a few seconds up to a couple minutes. This is normal operation for the test. NOTE: The P2262 diagnosis test MUST NOT be used after the repair is complete, as this test CANNOT be used to confirm the repair. Test results will be inaccurate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7411 If the customer is experiencing MIL illumination due to Diagnostic Trouble Code (DTC): P2262 Turbocharger Boost Pressure Not Detected - Mechanical follow the revised diagnosis and repair procedures below. NOTE: Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: While the wiTECH tool is the preferred method of testing and flashing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. NOTE: Please read through this entire Service Bulletin to gain a full understanding before performing the procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTC's button. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: DO NOT erase DTC's or reprogram the PCM at this point. If P2262 is not present in the PCM due to clearing the faults or reprogramming the PCM, the P2262 diagnosis test in Scan Tool will not run. NOTE: It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC's to be erased. 5. Is DTC P2262 present in the PCM? a. If YES >> Proceed to Step # 6. b. If NO >> Then STOP. This bulletin does not apply. 6. Confirm the engine coolant temperature is between 50°F and 180°F. 7. Perform the P2262 diagnostic test with wiTECH(R), From the "Vehicle View screen select: a. Select "PCM". b. Select "Systems Tests". c. Select "P2262 Fault Diagnosis Test Start". d. Follow on-screen prompts to complete test. NOTE: If you receive an error message from test, confirm that the Diagnostic Link Connector and turbocharger actuator harness connections are secure. Also confirm that engine coolant temperature is between 50°F and 180°F, then run the test again. 8. Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Based on these results, refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info and complete Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7412 the repair as directed; a. Update PCM Flash Calibration to the latest calibration. No repair required to the turbocharger. b. Clean the Turbocharger. c. Update PCM Flash Calibration to the latest calibration and Clean the Turbocharger. d. Replace the Turbocharger. e. Update PCM Flash Calibration to the latest calibration and Replace the Turbocharger. 9. Does the vehicle have other DTC's as recorded in Step # 4 above? a. Yes >> Follow appropriate diagnosis procedures or TSB related to diagnosis and repair of each fault. b. No >> Repair complete. NOTE: All other DTC's or symptoms MUST be addressed prior to returning the vehicle to the customer. NOTE: When/if replacing Turbocharger, p/n 68048234AA or 68031095AA must NOT be used on a D1/DH (Pick Up) models. Turbocharger p/n 68048234AA or 68031095AA are to be used on DA/DC/DM (Cab/Chassis) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls False Oil Change Indicator NUMBER: 18-005-08 REV. B GROUP: Vehicle Performance DATE: August 20, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-005-08 REV. A, DATED JUNE 13, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.05 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: FLASH: Turn Off Oil Change Indicator Message OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM). MODELS: **2008 (DR) Ram Truck (International Markets)** **2008 (HB) Durango (International Markets)** **2007 - 2008 (JK) Wrangler (International Markets)** **2007 (JK) wrangler** **2008 (KA) Nitro (International Markets)** **2008 (ND) Dakota (International Markets)** 2008 (WH) Grand Cherokee (International Markets) 2008 (XH) Commander (International Markets) NOTE: This bulletin applies to: - **2007 JK vehicles built with a 3.8L engine (sales code EGK) after June 17, 2008 (MDH 0617XX)** - **2008 JK vehicles built with a 3.8L engine (sales code EGK) before April 28, 2008 (MDH 0428XX)** - **2008 DR/HB/ND vehicles built with a 4.7L engine (sales code EVE )** - WK/WH vehicles built with a 4.7L engine (sales code EVE) built before January 25, 2008 (0125XXMDH) - KA vehicles equipped with a 4.0L engine (sales code EGS) built before July 8.2008 (MDH 0708XX) SYMPTOM/CONDITION: Some international vehicle's may experience message on the Electronic Vehicle Information Center (EVIC) or in the Odometer that tells the driver an oil change is necessary after 3000 miles. This message should not be displayed for these international vehicles and this PCM flash will turn this feature off. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If 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, perform the Repair Procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 7417 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.05 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 7418 j. Select "Update Controller". k. When the update is complete, select "OK". 7. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7423 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7424 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7429 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7430 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7431 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7432 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7433 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7434 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7435 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info PROM - Programmable Read Only Memory: All Technical Service Bulletins Diesel Engine Dust/Debris Ingestion/Power Upgrade Info NUMBER: 09-001-10 GROUP: Engine DATE: July 2, 2010 SUBJECT: Dust-Out Diagnosis For Cummins Diesel Engines OVERVIEW: This bulletin involves proper inspection procedures to determine engine failure due to dust-out condition. Engines damaged due to the infiltration of dirt and/or debris through the air intake system are NOT WARRANTABLE. NOTE: Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. MODELS: 2003 - 2005 (DR) Ram Pick Up Truck (2500) 2006 - 2009 (DH) Ram Pick Up Truck (2500) 2010 - 2011 (DJ) Ram Pick Up Truck (2500) 2003 - 2005 (DR) Ram Pick Up Truck (3500) 2006 - 2009 (D1) Ram Pick Up Truck (3500) 2010 - 2011 (D2) Ram Pick Up Truck (3500) 2007 - 2010 (DC) Ram Truck Cab Chassis (3500) 2011 (DD) Ram Truck Cab Chassis (3500) 2008 - 2010 (DM) Ram Truck Cab Chassis (4500/5500) 2011 (DP) Ram Truck Cab Chassis (4500/5500) NOTE: This bulletin applies to any Cummins diesel equipped vehicle still covered under the manufacturers warranty. SYMPTOM/CONDITION: Engines that exhibit particular symptoms that may have been caused by improper air filtration. Some of these symptoms are listed below (not limited to) ^ Knocking ^ Hard or no start ^ Low power / poor performance ^ Oil consumption ^ Lower end bearing failure ^ Smoking ^ Blow-by (rings not sealing) ^ Oil on turbo (dust damage to seal/bearing) NOTE: See the "Cummins Diesel Dust-Out Inspection for Warranty" document located in eFiles Under: Service> STAR Center> Cummins - HEV Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info > Page 7441 documents for pictures regarding dust-outs. NOTE: Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs. DIAGNOSIS: 1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect. 2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage. 3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles. NOTE: Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved). 6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls CCN Update For Recall J35 NUMBER: 18-016-10 GROUP: Vehicle Performance DATE: April 30, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-08 REV. A, DATED DECEMBER 4, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN INCLUDED. Either wiTECH, StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE or StarSCAN(R) can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.03 OR HIGHER. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER. SUBJECT: FLASH: CCN Update Required With J35 Recall OVERVIEW: This bulletin involves: - As stated in Recall J35, verify that Emission Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM has been performed. If not, perform Recall G30 first. - Verifying software level, and if necessary, selectively erasing and reprogramming the Cab Compartment Node (CCN) module with new software. - It is recommended to discuss with the customer any required necessary maintenance as suggested in the owners manual. Inform the customer the importance of properly maintaining their vehicle. Possible required maintenance items may include (not limited to) lube, oil change and filter service, air filter replacement, fuel filter replacement, and crankcase ventilation filter replacement and EGR valve cleaning based on customer use and mileage accumulation. CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. MODELS: 2007 - 2008 (DH) Ram Pick Up Truck (2500 Series) 2007 - 2008 (D1) Ram Pick Up Truck (3500 Series) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sale code ETJ). NOTE: 2009 MY vehicle had proper CCN software installed during production. SYMPTOM/CONDITION: NOTE: Many improvements have been addressed with the latest Engine Control Module (ECM) software addressed in Recall J35. The Cab Compartment Node (CCN) may require updating in conjunction with the Recall. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. DIAGNOSIS: If J35 Recall is being performed, verify the CCN is up to date with the latest software (flash) and that Recall G30 Has been performed. Using a Scan Tool (StarSCAN(R) / StarMOBILE(R)) with the appropriate Diagnostic Procedures available in TechCONNECT(R), verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 1. Is the vehicle eligible to have Emissions Recall G30 - Replace Oxygen Sensor Module and Reprogram ECM performed? Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7446 a. If YES then perform G30 Recall and then continue to Step # 2. b. If NO then proceed to Step # 2. 2. Using the scan tool, determine current software level of the CCN. Record on the repair order. Proceed to Step # 3. 3. Determine if the current CCN module level software part number, that was recorded earlier in Step # 2, is one of the following (or with a higher suffix): a. 05172187AG (or higher) = 2007 DH (2500) or 2007 D1 (3500). b. 05172334AG (or higher) = 2008 DH (2500) or 2008 D1 (3500). 4. Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step # 3? a. If YES then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. This bulletin is complete. b. If NO then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to REPAIR PROCEDURE. SPECIAL TOOLS / EQUIPMENT AS REQUIRED: NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. REPAIR PROCEDURE: NOTE: The repairs in this Service Bulletin (SB) only address the labor associated with the reprogramming of the CCN. Any other labor associated with the performance of additional diagnostics or repairs are not addressed by this SB and must be claimed separately. NOTE: Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. CN MODULE REPROGRAM - USING wiTECH(R): Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7447 WiTECH(R) SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER. 1. Connect the wiTECH(R) VCI pod to the vehicle data link connector located under the steering column. 2. Place the ignition in the "RUN" position. 3. Open the wiTECH(R) Diagnostic application. 4. Starting at the "Select Tool" screen, select the row/tool for the wiPOD(R) device you are using. 5. Enter your "User id" and "Password", then select "OK". 6. Select the "Next tab" at the bottom of the screen. 7. From the "Vehicle View" screen, click on the CCN icon. 8. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step # 14. If the part numbers are not the same, continue to Step # 9. 9. With the cursor over the desired flash file, click the green arrow button on the right side of the screen. 10. From the "ECU Flash screen" follow the wiTECH(R) screen instructions to complete the flash. 11. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 12. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTCs) by clicking the "Clear DTC's" button. 13. From the "CCN View" screen, compare the "Current ECU Flash Number" with the "New Part Number listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 9 through 13. 14. Turn the ignition to the "OFF" position, remove the wiPOD(R) and battery charger from the vehicle. CCN MODULE REPROGRAM - USING StarMOBILE(R): 1. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 2. Power ON the StarMOBILE(R) scan tool. 3. From the desktop, launch the "StarMOBILE(R) Desktop Client" software. 4. Establish a connection with the StarMOBILE scan tool. 5. Retrieve the old CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash CCN" screen for later reference. 6. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash CCN" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the CCN is up to date. Continue to Step # 7. If the part numbers are not the same, continue to Step 6d. d. Highlight the listed calibration on the StarMOBILE screen. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7448 e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 7. Disconnect the StarMOBILE vehicle cable from the vehicle. 8. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 9. Retrieve the CCN part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "CCN" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs). CCN MODULE REPROGRAM - USING StarSCAN(R): 1. Connect the CH941 0 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 2. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 3. Turn the ignition switch to the "RUN/ON" position. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN module part number and reprogram the CCN module. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash CCN" screen on the WRO for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the CCN module update is complete, select "OK". Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-10 > Apr > 10 > Computers/Controls - CCN Update For Recall J35 > Page 7449 CUSTOMER INFORMATION SHEET INCLUDED: Please print the "DIESEL EXHAUST AFTERTREATMENT SYSTEM" at the end of this bulletin for customer reference. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: DIESEL EXHAUST AFTERTREATMENT SYSTEM Your vehicle is equipped with a Diesel Particulate Filter (DPF) which is used to clean the exhaust. The DPF (exhaust filter) will self clean as part of normal vehicle operation. In some cases, your intervention may be required to allow the self-cleaning process to occur. WHAT YOU WILL SEE IN THE OVERHEAD DISPLAY ^ "ExhaustFilter xx% Full" - Indicates that the DPF is approaching full. ^ "Regeneration Required Now" - Indicates you will need to intervene by changing your driving mode. See Owner Manual. ^ "Regeneration in Process" - Indicates the DPF is self-cleaning. Please try to maintain you current driving condition until regeneration is complete. ^ "Regeneration Completed" - DPF self-cleaning is complete. ^ "Service Required-See Dealer Now" - Indicated DPF regeneration is not functioning. Your Check Engine Light (MIL) may come on. Please see dealer. IMMEDIATE SERVICE IS REQUIRED. Damage to the exhaust system could occur soon with continued operation. ^ "Exhaust Filter FULL - Power Reduced - See Dealer" - Your DPF is full. Engine power will be reduced to decrease risk of damage. IMMEDIATE SERVICE IS REQUIRED. Please see dealer immediately. Damage to the exhaust system will occur with continued operation. For additional assistance contact Chrysler. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P2262 Set NUMBER: 09-002-09 GROUP: Engine DATE: May 23, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-001-08 and 11-002-08 BOTH DATED MAY21, 2008. THIS ISA COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE STANDALONE MODE OR StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: MIL Illumination Due to DIG P2262 - Revised Diagnosis and Repair Procedures OVERVIEW: This bulletin discusses revised diagnostic and repair procedures for DTC P2262 Turbocharger Boost Pressure Not Detected - Mechanical. Recent PGM calibration updates have improved the robustness to this DIG through updated diagnostic strategies. As a result, many events which have no adverse affects on drivability, emissions, or reliability will no longer set the P2262 fault. MODELS: 2007 - 2009 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicle equipped with a Cummins 6.7L engine (sales code ETJ). DISCUSSION: Malfunction Indicator Lamp (MIL) illumination due to Diagnostic Trouble Code (DTC): P2262 - Turbocharger Boost Pressure Not Detected - Mechanical. As a result of recent PCM calibration updates, the proper repair for some P2262 faults is to just update the calibration, while others will require cleaning or replacing the turbocharger. Scan Tool software update 9.05 (and later) includes a P2262 diagnosis test for this purpose. This diagnostic test uses Freeze Frame data stored in the PCM and a dynamic turbocharger response test to determine the correct repair for each truck with DTC P2262. The new P2262 diagnosis test must be used prior to performing any of the following: ^ Clearing codes. ^ Updating the PCM. ^ Beginning the turbocharger repair. The test must be used with the key in the run position with the engine off, and with coolant temperature between 50°F and 180° F. The time required to run this test will vary with the calibration level of the truck, from a few seconds up to a couple minutes. This is normal operation for the test. NOTE: The P2262 diagnosis test MUST NOT be used after the repair is complete, as this test CANNOT be used to confirm the repair. Test results will be inaccurate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7454 If the customer is experiencing MIL illumination due to Diagnostic Trouble Code (DTC): P2262 Turbocharger Boost Pressure Not Detected - Mechanical follow the revised diagnosis and repair procedures below. NOTE: Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: While the wiTECH tool is the preferred method of testing and flashing, StarMOBILE desktop client, StarMOBILE standalone mode OR StarSCAN may also be used to perform this procedure. NOTE: Please read through this entire Service Bulletin to gain a full understanding before performing the procedure. DIAGNOSIS: 1. Connect the Scan Tool to the Diagnostic Link Connector (DLC). 2. Turn the ignition key to the RUN position, DO NOT start the engine. 3. From the "Vehicle View" screen on the Scan Tool select: a. "All DTC's button. 4. Record all Diagnostic Trouble Codes (DTC's) that are present in the PCM. NOTE: DO NOT erase DTC's or reprogram the PCM at this point. If P2262 is not present in the PCM due to clearing the faults or reprogramming the PCM, the P2262 diagnosis test in Scan Tool will not run. NOTE: It is IMPORTANT to record (capture) all DTC's present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC's to be erased. 5. Is DTC P2262 present in the PCM? a. If YES >> Proceed to Step # 6. b. If NO >> Then STOP. This bulletin does not apply. 6. Confirm the engine coolant temperature is between 50°F and 180°F. 7. Perform the P2262 diagnostic test with wiTECH(R), From the "Vehicle View screen select: a. Select "PCM". b. Select "Systems Tests". c. Select "P2262 Fault Diagnosis Test Start". d. Follow on-screen prompts to complete test. NOTE: If you receive an error message from test, confirm that the Diagnostic Link Connector and turbocharger actuator harness connections are secure. Also confirm that engine coolant temperature is between 50°F and 180°F, then run the test again. 8. Based on the outcome of the P2262 diagnosis test, the Scan Tool will provide one of the following as the proper direction for the appropriate repair. Based on these results, refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info and complete Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-002-09 > May > 09 > Engine Controls - MIL ON/DTC P2262 Set > Page 7455 the repair as directed; a. Update PCM Flash Calibration to the latest calibration. No repair required to the turbocharger. b. Clean the Turbocharger. c. Update PCM Flash Calibration to the latest calibration and Clean the Turbocharger. d. Replace the Turbocharger. e. Update PCM Flash Calibration to the latest calibration and Replace the Turbocharger. 9. Does the vehicle have other DTC's as recorded in Step # 4 above? a. Yes >> Follow appropriate diagnosis procedures or TSB related to diagnosis and repair of each fault. b. No >> Repair complete. NOTE: All other DTC's or symptoms MUST be addressed prior to returning the vehicle to the customer. NOTE: When/if replacing Turbocharger, p/n 68048234AA or 68031095AA must NOT be used on a D1/DH (Pick Up) models. Turbocharger p/n 68048234AA or 68031095AA are to be used on DA/DC/DM (Cab/Chassis) ONLY. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls False Oil Change Indicator NUMBER: 18-005-08 REV. B GROUP: Vehicle Performance DATE: August 20, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-005-08 REV. A, DATED JUNE 13, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.05 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: FLASH: Turn Off Oil Change Indicator Message OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM). MODELS: **2008 (DR) Ram Truck (International Markets)** **2008 (HB) Durango (International Markets)** **2007 - 2008 (JK) Wrangler (International Markets)** **2007 (JK) wrangler** **2008 (KA) Nitro (International Markets)** **2008 (ND) Dakota (International Markets)** 2008 (WH) Grand Cherokee (International Markets) 2008 (XH) Commander (International Markets) NOTE: This bulletin applies to: - **2007 JK vehicles built with a 3.8L engine (sales code EGK) after June 17, 2008 (MDH 0617XX)** - **2008 JK vehicles built with a 3.8L engine (sales code EGK) before April 28, 2008 (MDH 0428XX)** - **2008 DR/HB/ND vehicles built with a 4.7L engine (sales code EVE )** - WK/WH vehicles built with a 4.7L engine (sales code EVE) built before January 25, 2008 (0125XXMDH) - KA vehicles equipped with a 4.0L engine (sales code EGS) built before July 8.2008 (MDH 0708XX) SYMPTOM/CONDITION: Some international vehicle's may experience message on the Electronic Vehicle Information Center (EVIC) or in the Odometer that tells the driver an oil change is necessary after 3000 miles. This message should not be displayed for these international vehicles and this PCM flash will turn this feature off. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If 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, perform the Repair Procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 7460 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.05 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-005-08B > Aug > 08 > Engine Controls - False Oil Change Indicator > Page 7461 j. Select "Update Controller". k. When the update is complete, select "OK". 7. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7466 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7467 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 09-001-10 > Jul > 10 > Diesel Engine - Dust/Debris Ingestion/Power Upgrade Info > Page 7473 documents for pictures regarding dust-outs. NOTE: Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs. DIAGNOSIS: 1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect. 2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage. 3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage. 5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles. NOTE: Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved). 6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration Technical Service Bulletin # J35 Date: 100416 Recall - ECM Update For Exhaust Regeneration April 2010 Dealer Service Instructions for: Emissions Recall J35 Reprogram ECM Regeneration Strategy Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) 09-086 and Technical Service Bulletin (TSB) # 18-024-09 rev. A have been cancelled. All vehicles that have previously had the above RRT or TSB completed will require this Recall. Models 2007-2009 (DH/D1) Dodge Ram Truck (2500/3500 series) NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine (sales code ETJ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Engine Control Module (ECM) software program on about 159,700 of the above vehicles may cause illumination of the Malfunction Indicator Lamp (MIL) when no problem exists or under certain conditions allow heavy sooting of the turbocharger, exhaust gas recirculation valve and diesel particulate filter. Heavy sooting could damage emissions components and result in increased emissions. Repair The Engine Control Module must be reprogrammed (flashed). Parts Information Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed. Each vehicle requires application of the following label: Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7478 The following special tools are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7479 GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure NOTE: Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall. This procedure must be performed with software release level 10.02 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure. A. Reprogram the ECM Using wiTECH: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column. 3. Place the ignition in the "RUN" position. 4. Open the wiTECH Diagnostic application. 5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using. 6. Enter your "User id" and "Password", then select "OK". 7. Select the "Next" tab at the bottom of the screen. 8. From the "Vehicle View" screen, click on the PCM icon. 9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10. 10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen. 11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash. 12. Once the flash is complete click the "OK" button on the "ECU Flash" screen. 13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's button. 14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7480 ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14. 15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle. 16. Continue with Section D. Install Authorized Modifications Label. B. Reprogram the ECM Using StarSCAN: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select "Browse for New File". Follow the on screen instructions. b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c. c. Highlight the listed calibration on the StarSCAN screen. d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select "OK". 7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK". 8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle. 9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7481 a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle. 12. Continue with Section D. Install Authorized Modification Label. C. Reprogram the ECM Using StarMOBILE: CAUTION: On 2007 model year trucks, verify that Emissions Recall G30 has been completed prior to performing this notification. Recall G30 contains "bootloader" software that must be installed to prevent damage to the ECM. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power ON the StarMOBILE scan tool. 4. From the desktop, launch the "StarMOBILE Desktop Client" software. 5. Establish a connection with the StarMOBILE scan tool. 6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference. 7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7482 a. Select "Browse for New File". Follow the on screen instructions. b. Enter your "User id" and "Password", then select "OK". c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 12. If the part numbers are not the same, continue to Step 7d. d. Highlight the listed calibration on the StarMOBILE screen. e. Select "Download to Client". f. Select "Close" after the download is complete, then select the "Back" arrow. g. Highlight the listed calibration. h. Select "Update Controller" and follow the on screen instructions. i. When the update is completed, select "OK". 8. Disconnect the StarMOBILE vehicle cable from the vehicle. 9. Turn off the StarMOBILE scan tool and then restart the scan tool. NOTE: The StarMOBILE scan tool must be shut down and restarted to unlock the flash. 10. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Select "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. 11. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 12. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle. 13. Continue with Section D. Install Authorized Modification Label. D. Install the Authorized Modifications Label: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7483 1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1). 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. NOTE: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > J35 > Apr > 10 > Recall - ECM Update For Exhaust Regeneration > Page 7484 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update Technical Service Bulletin # G30 Date: 071001 Recall - O2 Sensor Replacement/ECM Software Update October 2007 Dealer Service Instructions for: Emissions Recall G30 Replace Oxygen Sensor Module and Reprogram ECM Effective immediately all repairs on involved vehicles are to be performed according to this recall. Rapid Response Transmittal (RRT) 07-037 and Service Bulletin # 18-033-07 are being cancelled. Models 2007 - 2008 (DH/D1) Dodge Ram 2500/3500 Pick Up Truck NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine ("A" in the 8th VIN position) built through August 20, 2007 (MDH 082019). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The On-Board Diagnostic (OBD) system on about 74,000 of the above vehicles may not detect a failed oxygen sensor or illuminate the Malfunction Indicator Light as required. In addition, the OBD system may cause these trucks to fail an Inspection Maintenance (Readiness) test and may not store mileage as required for certain transmission faults. Repair The Oxygen Sensor Module must be replaced and the Engine Control Module (ECM) must be reprogrammed (flashed). NOTE: The new software will also improve vehicle driveability and reduce the potential for exhaust soot accumulation in the vehicle's particulate filter. Parts Information Special Tools Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7489 These existing special tools may be required to perform this repair shown. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow up Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7490 All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler LLC A. Replace the Oxygen Sensor Module 1. Open the hood and disconnect the negative battery cables from both batteries. 2. Using a mechanic's creeper, slide under the right side of the truck and locate the oxygen sensor module on the outer side of the right frame rail (Figure 1). 3. Disconnect the electrical connector at the oxygen sensor module (Figure 1). 4. Remove the four oxygen sensor module mounting bolts (Figure 1). 5. Remove and discard the original oxygen sensor module from frame rail. 6. Position the new oxygen sensor module onto the frame rail. 7. Install the four oxygen sensor module mounting bolts. 8. Tighten the oxygen sensor module mounting bolts to 53 in. lbs. (6 N.m). 9. Connect the oxygen sensor module electrical connector to the module. 10. Connect the negative battery cables. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7491 11. Continue with Section B - Check ECM Software Level. B. Check ECM Software Level 1. Connect the StarSCAN to the vehicle. 2. Turn the vehicle ignition switch to the "ON/RUN" position (engine not running). 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Power up the StarSCAN and verify that the StarSCAN is at software release 8.03 or higher. NOTE: The software release level is visible in the blue header at the top of the StarSCAN screen. 5. Starting from the "Home" screen, select "ECU View". 6. Touch the StarSCAN screen to highlight the "PCM Powertrain Control Module" in the list of modules. 7. Select "More Options". 8. Select "ECU Flash". 9. Record the part number of the Application software file in the ECM. 10. Determine if the application software file part number currently in the ECM is one of the following part numbers (or the same root part number with a higher suffix - last two digits): If the current application software file part number in the ECM matches one of the above part numbers (or the same root part number with a higher suffix - last two digits), no further action is required. Disconnect the StarSCAN and continue with Section D. Install Authorized Modifications Label. If the current application software file part number in the ECM does not match one of the above part numbers, continue with Section C. Program the ECM. C. Program the ECM NOTE: This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure. NOTE: Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. CAUTION: On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7492 NOTE: Do not allow the charging voltage to exceed 13.5 volts during the flash process. 2. Make sure the ignition is in the "RUN" position. 3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure. For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure. 4. Erase all flash files from the StarSCAN using the following procedure: a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen. b. Select "Tool Menu" button in the upper left corner of the screen. c. Select "Manage Files". d. Select "More Options". e. Select "Delete All". f. Select "Yes" on the pop-up screen. g. Select "OK" on the pop-up screen. h. Select "Back" at the "User's Files" menu. 5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure: a. Select "ECU View". b. Select "(PCM) Powertrain Control Module" from the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx"). f. Select "Browse for New File". g. Select "OK" at the flash down load screen. h. Enter the required data and select "OK" at the password screen. i. Select "Finish". j. Highlight the ECM "Bootloader" software file. CAUTION: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number. k. Select "Download to Scantool". l. Select "Close" on the pop-up screen when the download is complete. m. Select "Back" one (1) time. CAUTION: When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement. 6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7493 7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure: a. Highlight the "Bootloader" software selected previously. NOTE: The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU flash. d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete. e. Select "Back" three (3) times to return to the "ECU View" screen. 8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes. 9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine). 10. Confirm that the ECM has the new "Bootloader" software using the following procedure: a. From the "ECU View" screen, select "PCM" in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM. 11. Erase the "Bootloader" software file from the StarSCAN using the following procedure: a. Starting at the "Flash PCM" screen, select "Manage Files". b. Highlight the "Bootloader" software file listed in the StarSCAN memory. c. Select "Delete". d. Select "YES" on the pop-up screen. e. Select the "BACK" button five (5) times. 12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed). 13. Select "PCM Powertrain Control Module". 14. Select "More Options". 15. Select "ECU Flash". 16. Download the ECM application software file to the StarSCAN using the following procedure: a. Select "Browse for New File". b. Select "OK" at the Flash Download screen. c. Enter the required data and select "OK" at the password screen. d. Select "Finish" at the "Flash Update" screen to display download results. e. Select the application software file. NOTE: The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7494 f. Highlight the application software file for download to the StarSCAN. g. Select "Download to Scantool". h. Select "Close" at the "Download File" screen when the download is complete. i. After the file has been downloaded, select "Back" one (1) time. 17. Reprogram the ECM with new application software from the StarSCAN using the following procedure: a. Highlight the application software file to be downloaded. b. Select "Update Controller". c. Select "OK" at the ECU Flash screen. d. Wait for the software file to download to the ECM. e. Select "OK" at the "Flash ECU Successful" screen after the download is complete. 18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file. 19. Select "Back" four (4) times to return to the "Home" screen. 20. Turn the ignition switch to the "OFF" position and wait 10 seconds. 21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure: a. Place the ignition switch to the "RUN" position (do not start the engine). b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position and wait 10 seconds. g. Start the engine to verify that all DTC's have been erased. h. Turn the ignition switch to the "OFF" position. 22. Turn off and disconnect the battery charger. 23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label. D. Install Authorized Modifications Label 1. Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > G30 > Oct > 07 > Recall - O2 Sensor Replacement/ECM Software Update > Page 7495 2. Attach the label near the VECI label and then close the hood. 3. Complete Proof of Correction Form for California Residents. Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 7503 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7506 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7511 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7512 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7513 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7514 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7515 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7516 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7517 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7518 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7519 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7520 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7521 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7522 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7523 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7524 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7527 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7528 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7529 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7530 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7531 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7532 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7533 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7534 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7535 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7536 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7537 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7538 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7539 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7540 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 7543 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7546 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 455 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Circuit Description 1 K32 18DB/YL BTSI SOLENOID CONTROL 2 Z101 18BK/VT GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7550 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7551 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7552 Shift Interlock Solenoid: Diagrams Component ID: 455 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Circuit Description 1 K32 18DB/YL BTSI SOLENOID CONTROL 2 Z101 18BK/VT GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7553 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7554 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7559 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7560 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7561 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7562 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7563 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7564 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7565 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7566 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7567 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7568 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7569 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7570 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7571 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 20 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T60 20YL/GY OD CONTROL 2 T59 20YL/LB UD CONTROL 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 4 T19 18YL/DB 2-4 CONTROL 5 T47 18YL/DG 2-4 PRESSURE SIGNAL 6 T9 20DG/TN OD PRESSURE SIGNAL 7 T20 20DG/WT L/R CONTROL 8-9-10 T50 20YL/TN L/R PRESSURE SIGNAL Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7572 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7573 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7574 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7577 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7578 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7579 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7580 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7581 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7582 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7583 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7584 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7585 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7586 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7587 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7588 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7589 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7590 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 7593 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7596 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 7600 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7603 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA See: Adjustments . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 7609 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 7610 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 202 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Circuit Description 1 Z906 20BK GROUND 2 G304 20VT/DB FRONT AXLE LOCK CONTROL 3 A880 20DB/RD FUSED B(+) 4 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7615 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7616 Solenoid: Locations Solenoid-Locker-Front Component ID: 457 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T520 16YL/OR FRONT LOCKER SOURCE 2 T521 18YL/BK LOCKER SENSOR SUPPLY 3 T522 18YL/LB FRONT LOCKER SENSOR SENSE 4 T524 16YL/LG FRONT LOCKER RETURN Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7617 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7618 Solenoid: Locations Solenoid-Locker-Rear Component ID: 458 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T526 16YL/WT REAR LOCKER SOURCE 2 T523 18YL/BK LOCKER SENSOR SUPPLY 3 T527 18YL/TN REAR LOCKER SENSOR SENSE 4 T528 16YL/GY REAR LOCKER RETURN Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 7619 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 202 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Circuit Description 1 Z906 20BK GROUND 2 G304 20VT/DB FRONT AXLE LOCK CONTROL 3 A880 20DB/RD FUSED B(+) 4 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7622 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7623 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 457 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T520 16YL/OR FRONT LOCKER SOURCE 2 T521 18YL/BK LOCKER SENSOR SUPPLY 3 T522 18YL/LB FRONT LOCKER SENSOR SENSE 4 T524 16YL/LG FRONT LOCKER RETURN Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7624 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7625 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 458 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T526 16YL/WT REAR LOCKER SOURCE 2 T523 18YL/BK LOCKER SENSOR SUPPLY 3 T527 18YL/TN REAR LOCKER SENSOR SENSE 4 T528 16YL/GY REAR LOCKER RETURN Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 7626 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations Transfer Case Actuator: Locations Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7631 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7632 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7633 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7634 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7635 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Page 7636 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 Transfer Case Actuator: Diagrams Component ID 14 Component ID: 14 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 7639 Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 7640 Transfer Case Actuator: Diagrams Component ID 18 Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 7641 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 7642 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 7643 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 7644 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 7645 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Component ID 14 > Page 7646 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case Transfer Case Actuator: Description and Operation NV243 Transfer Case Description DESCRIPTION The shift motor (2) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Description DESCRIPTION The shift motor (2) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7649 Transfer Case Actuator: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The shift motor (2) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7650 Transfer Case Actuator: Description and Operation NV246 Transfer Case Description DESCRIPTION The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Front Control Module (FCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > NV243 Transfer Case > Page 7651 Transfer Case Actuator: Description and Operation NV273 Transfer Case Description DESCRIPTION The shift motor (2) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 23° C (72° F) with 10 volts at the motor leads. Operation OPERATION The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case Transfer Case Actuator: Service and Repair NV243 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts (3) holding the shift motor and mode sensor assembly (2) onto the transfer case (1). 4. Separate the shift motor and mode sensor assembly (2) from the transfer case. Installation INSTALLATION 1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly (2) onto the transfer case (1). 3. Install the bolts (3) to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7654 Transfer Case Actuator: Service and Repair NV244 GENII Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts (3) holding the shift motor and mode sensor assembly (2) onto the transfer case (1). 4. Separate the shift motor and mode sensor assembly (2) from the transfer case. Installation INSTALLATION 1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly (2) onto the transfer case (1). 3. Install the bolts (3) to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7655 Transfer Case Actuator: Service and Repair NV246 Transfer Case Removal REMOVAL 1. Raise the vehicle on a suitable hoist. 2. Remove the front propeller shaft. See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement 3. Disengage the wiring connectors from the shift motor and mode sensor. 4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case. 5. Separate the shift motor and mode sensor assembly (1) from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7656 6. Remove the shift motor isolator (1) from the transfer case (2). Installation INSTALLATION 1. Install the shift motor isolator (1) onto the transfer case (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7657 NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Install the shift motor and mode sensor assembly (1) onto the transfer case. CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 3. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) onto the transfer case. Tighten the bolts to 23.5 Nm (17 ft.lbs.). 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Install the front propeller shaft. See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement 6. Refill the transfer case as necessary with the correct fluid for the application. 7. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > NV243 Transfer Case > Page 7658 Transfer Case Actuator: Service and Repair NV273 Transfer Case Removal REMOVAL NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal. 1. Raise the vehicle on a suitable hoist. 2. Disengage the wiring connectors from the shift motor and mode sensor. 3. Remove the bolts (3) holding the shift motor and mode sensor assembly (2) onto the transfer case (1). 4. Separate the shift motor and mode sensor assembly (2) from the transfer case. Installation INSTALLATION 1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned. 2. Position the shift motor and mode sensor assembly (2) onto the transfer case (1). 3. Install the bolts (3) to hold the assembly onto the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft.lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts 4. Engage the wiring connectors to the shift motor and mode sensor. 5. Refill the transfer case as necessary. 6. Lower vehicle and verify transfer case operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 7665 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7668 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7673 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7674 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7675 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7676 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7677 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7678 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7679 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7680 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7681 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7682 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7683 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7684 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7685 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7686 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7689 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7690 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7691 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7692 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7693 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7694 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7695 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7696 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7697 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7698 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7699 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7700 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7701 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7702 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 7705 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7708 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 455 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Circuit Description 1 K32 18DB/YL BTSI SOLENOID CONTROL 2 Z101 18BK/VT GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7712 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7713 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7714 Shift Interlock Solenoid: Diagrams Component ID: 455 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Circuit Description 1 K32 18DB/YL BTSI SOLENOID CONTROL 2 Z101 18BK/VT GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7715 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 7716 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7721 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7722 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7723 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7724 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7725 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7726 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7727 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7728 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7729 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7730 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7731 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7732 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7733 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 20 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T60 20YL/GY OD CONTROL 2 T59 20YL/LB UD CONTROL 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 4 T19 18YL/DB 2-4 CONTROL 5 T47 18YL/DG 2-4 PRESSURE SIGNAL 6 T9 20DG/TN OD PRESSURE SIGNAL 7 T20 20DG/WT L/R CONTROL 8-9-10 T50 20YL/TN L/R PRESSURE SIGNAL Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7734 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7735 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7736 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7739 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7740 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7741 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7742 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7743 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7744 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7745 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7746 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7747 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7748 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7749 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7750 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7751 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7752 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 7755 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7758 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 7762 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7765 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA See: Adjustments . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair Accumulator: Service and Repair INSPECTION Inspect the accumulator piston and seal rings. Replace the seal rings if worn or cut. Replace the piston if chipped or cracked. Check condition of the accumulator inner and outer springs. Replace the springs if the coils are cracked, distorted or collapsed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7777 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7778 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7784 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7785 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 Control Module: Locations Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7788 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7789 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7790 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7791 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7792 Control Module: Locations Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7793 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7794 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7795 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7796 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 Control Module: Diagrams Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7799 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7800 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7801 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7802 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7803 Control Module: Diagrams Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7804 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7805 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7806 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 7807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7810 On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7811 Control Module: Description and Operation Transmission Control Module - Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7812 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7813 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7814 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 7815 Some examples of TCM.indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 7821 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 7826 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 7827 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 7828 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 7829 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Service Fill 42RLE .................................................................................................................................................. ............................................................. 3.8L (4.0 Qt) 45RFE/545RFE 4X2 ............................................................................................................................ .......................................................................................... 5.2 (5.5 Qt) 4X4 ........................................ .............................................................................................................................................................. .............. 6.2L (6.5 Qt) 48RE .................................................................................................................................................... ............................................................. 3.8L (4.0 Qt) 68RFE 4X2 .......................................................................................................................................... ............................................................................ 5.2 (5.5 Qt) 4X4 ...................................................... .............................................................................................................................................................. 6.2L (6.5 Qt) AS68RC ............................................................................................................................................... ............................................................. 6.8L (7.2 Qt) Overhaul * 42RLE .................................................................................................................................................. ............................................................. 8.3L (8.7 Qt) 45RFE/545RFE ................................................................................................................................... ............................................... 14-16L (14.8-16.9 Qt) 48RE .................................................................................................................................................... ............................................... 14-16L (14.8-16.9 Qt) 68RFE ................................................................................................................................................. .......................................... 15.6-16.6L (16.4-17.5 Qt) AS68RC ............................................................................................................................................... .......................................................... 13L (13.74 Qt) *Dry fill capacity. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 7832 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid ............................................................................................................. .......................................................... Mopar ATF +4 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Description and Operation > Description Fluid - A/T: Description and Operation Description AUTOMATIC TRANSMISSION FLUID AUTOMATIC TRANSMISSION (ALL BUT AISIN TRANSMISSION) NOTE: Refer to fluid level checking procedures. Mopar(R) ATF +4, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler automatic transmissions. Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Mopar(R) ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. AISIN TRANSMISSION Mopar(R) AS68RC, Automatic Transmission Fluid is the recommended fluid for AISIN AS68RC TRANSMISSION. Mopar(R) AS68RC, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. Mopar(R) AS68RC, also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. FLUID ADDITIVES Chrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of Chrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Description and Operation > Description > Page 7835 Fluid - A/T: Description and Operation Operation OPERATION - AUTOMATIC TRANSMISSION FLUID The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain consistent. Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission Fluid - A/T: Testing and Inspection 68RFE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 7838 Fluid - A/T: Testing and Inspection 48RE Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has two primary causes. 1. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 2. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > 68RFE Automatic Transmission > Page 7839 Fluid - A/T: Testing and Inspection AS68RC Automatic Transmission Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid. - failure to clean dipstick and fill tube when checking level. - engine coolant entering the fluid. - internal failure that generates debris. - overheat that generates sludge (fluid breakdown). - failure to replace contaminated converter after repair. The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid - A/T: Service and Repair 68RFE Automatic Transmission Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT For proper service intervals See: Maintenance . REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the appropriate diagnostic procedure. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7842 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Fluid Level Check - 68RFE FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. FILL TUBE EQUIPPED WITH INDICATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7843 68RFE FLUID FILL CHART NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. CAPPED FILL TUBE 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336 into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7844 6. Check transmission oil temperature using the appropriate scan tool. NOTE: The true transmission oil temperature can only be read by a scan tool in REVERSE or any forward gear position. 7. The transmission Oil Dipstick 9336 has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil level is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7845 Fluid - A/T: Service and Repair 48RE Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. The transmission fluid level can be checked two ways. PROCEDURE ONE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick (1) and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough Mopar(R) ATF +4 to restore correct level. Do not overfill. PROCEDURE TWO Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7846 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into NEUTRAL. 5. Hook up scan tool and select engine. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT For proper service intervals See: Maintenance . The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7847 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7848 appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. See: Service and Repair/Procedures/48RE (A-618) 4 Speed/Transmission Fill 48RE Transmission Fill - 48RE TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) ATF +4 to transmission: a. If only fluid and filter were changed, add 3 pints (1-1/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7849 Fluid - A/T: Service and Repair AS68RC Automatic Transmission Fluid Level Check FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the gear train churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82° C. or 180° F), the fluid level is correct if it is in the HOT region (cross-hatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21° C (70° F) fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. Optimum fluid temperature for checking the level should be between 70°C (158°F) and 80°C ( 176°F). 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Connect the scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7850 NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid And Filter Replacement FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7851 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and o-ring seal from the valve body (1). INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the appropriate diagnostic procedure. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7852 TRANSMISSION OIL FILTER 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. See: Service and Repair/Procedures/AS68RC Automatic Transmission/Transmission Fill - AS68RC Transmission Fill - AS68RC TRANSMISSION FILL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7853 To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar(R) AS68RC ATF to transmission: a. If only fluid and filter were changed, add 6.8L (7.2 quarts) of AS68RC to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 13L (13.75 quarts) of Mopar(R) AS68RC ATF to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Fluid Filter - A/T: Service and Repair 68RFE Automatic Transmission FLUID AND FILTER REPLACEMENT For proper service intervals See: Maintenance . REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Transmission Filters - 4X4 Shown 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the appropriate diagnostic procedure. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7858 Transmission Filters - 4X4 Shown CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with Installer 6960-A or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (84 in.lbs.). 5. Place bead of Mopar(R) RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 in. lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR(R) ATF +4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7859 Fluid Filter - A/T: Service and Repair 48RE Automatic Transmission FLUID AND FILTER REPLACEMENT For proper service intervals See: Maintenance . The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan (3). 3. Remove bolts holding front and sides of pan to transmission (1). 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan and reusable gasket (2) away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolt holding pan to transmission. 7. While holding pan level, lower pan and gasket away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove screws holding filter (2) to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used trans fluid and filter properly. INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7860 1. Position a new transmission oil filter (2) onto the valve body. 2. Install the screws to hold the filter to the valve body. Tighten the screws to 4 Nm (35 in.lbs.). 3. Clean the gasket surfaces of the transmission oil pan (3) and transmission pan rail. NOTE: The transmission pan oil gasket (2) is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall. 4. Position the oil pan gasket (2) onto the oil pan (3). 5. Position the oil pan and gasket onto the transmission and install several bolts to hold the pan and gasket to the transmission. 6. Install the remainder of the oil pan bolts. Tighten the bolts to 13.6 Nm (125 in.lbs.). 7. Lower vehicle and fill transmission. See: Service and Repair/Procedures/48RE (A-618) 4 Speed/Transmission Fill 48RE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7861 Fluid Filter - A/T: Service and Repair AS68RC Automatic Transmission FLUID AND FILTER REPLACEMENT REMOVAL DRAIN PLUG 1. Raise vehicle. 2. Place a large diameter drain pan beneath the transmission pan. 3. Remove the drain plug bolt (1) and allow the oil to drain from the transmission pan. 4. Remove the drain pan bolts from the transmission case. 5. Remove the drain pan. TRANSMISSION OIL FILTER 6. Remove the transmission oil filter bolts (3). 7. Remove the transmission oil filter and o-ring seal from the valve body (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7862 INSPECTION OIL PAN MAGNETS Inspect bottom of pan, pick-up magnets (1) and magnetic drain plug (2) and fluid filter for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to the appropriate diagnostic procedure. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION TRANSMISSION OIL FILTER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 7863 1. Lubricate the transmission oil filter seal with MOPAR(R) AS68RC ATF. 2. Install the new transmission oil filter (2) in position on valve body (1) and into the oil pump. 3. Install the transmission oil filter bolts (3). 4. Tighten bolts to 10 Nm ( 88 in.lbs. ) torque. 5. Install a new transmission oil pan gasket. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 7 Nm (62 in. lbs.) torque. DRAIN PLUG 8. Install transmission drain plug bolt (1). 9. Tighten oil pan drain plug to 27 Nm ( 20 ft.lbs) torque. 10. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. See: Service and Repair/Procedures/AS68RC Automatic Transmission/Transmission Fill - AS68RC Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 68RFE Automatic Transmission Fluid Pan: Specifications 68RFE Automatic Transmission Transmission Pan Tighten pan bolts to 12 Nm (105 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 68RFE Automatic Transmission > Page 7868 Fluid Pan: Specifications 48RE Automatic Transmission Transmission Pan Tighten pan bolts to 13.6 Nm (125 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 68RFE Automatic Transmission > Page 7869 Fluid Pan: Specifications AS68RC Automatic Transmission Transmission Pan Tighten pan bolts to 7 Nm (62 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7873 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7874 Fluid Pressure Sensor/Switch: Diagrams Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7875 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 7878 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 7881 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Description Governor: Description and Operation Description DESCRIPTION Governor pressure is controlled electronically. Components used for governor pressure control include: - Governor body - Valve body transfer plate - Governor pressure solenoid valve - Governor pressure sensor - Fluid temperature thermistor - Throttle position sensor (TPS) - Transmission speed sensor - Powertrain control module (PCM) GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve (2) is a duty-cycle solenoid which regulates the governor pressure needed for upshifts and downshifts. It is an electro-hydraulic device located in the governor body on the valve body transfer plate. GOVERNOR BODY, TRANSFER PLATE, AND PRESSURE SENSOR The governor pressure sensor (2) measures output pressure of the governor pressure solenoid valve. The transfer plate is designed to supply transmission line pressure to the governor pressure solenoid valve and to return governor pressure. The governor pressure solenoid valve is mounted in the governor body (1). The body is bolted to the lower side of the transfer plate. GOVERNOR PRESSURE CURVES There are four governor pressure curves programmed into the transmission control module. The different curves allow the control module to adjust governor pressure for varying conditions. One curve is used for operation when fluid temperature is at, or below, -1°C (30°F). A second curve is used when fluid temperature is at, or above, 10°C (50°F) during normal city or highway driving. A third curve is used during wide-open throttle operation. The fourth curve is used when driving with the transfer case in low range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Description > Page 7886 Governor: Description and Operation Operation OPERATION Compensation is required for performance variations of two of the input devices. Though the slope of the transfer functions is tightly controlled, offset may vary due to various environmental factors or manufacturing tolerances. The pressure transducer is affected by barometric pressure as well as temperature. Calibration of the zero pressure offset is required to compensate for shifting output due to these factors. Normal calibration will be performed when sump temperature is above 50 degrees F, or in the absence of sump temperature data, after the first 10 minutes of vehicle operation. Calibration of the pressure transducer offset occurs each time the output shaft speed falls below 200 RPM. Calibration shall be repeated each 3 seconds the output shaft speed is below 200 RPM. A 0.5 second pulse of 95% duty cycle is applied to the governor pressure solenoid valve and the transducer output is read during this pulse. Averaging of the transducer signal is necessary to reject electrical noise. Under cold conditions (below 50 degrees F sump), the governor pressure solenoid valve response may be too slow to guarantee 0 psi during the 0.5 second calibration pulse. Calibration pulses are continued during this period, however the transducer output valves are discarded. Transducer offset must be read at key-on, under conditions which promote a stable reading. This value is retained and becomes the offset during the "cold" period of operation. GOVERNOR PRESSURE SOLENOID VALVE The inlet side of the solenoid valve is exposed to normal transmission line pressure. The outlet side of the valve leads to the valve body governor circuit. The solenoid valve regulates line pressure to produce governor pressure. The average current supplied to the solenoid controls governor pressure. One amp current produces zero kPa/psi governor pressure. Zero amps sets the maximum governor pressure. The powertrain control module (PCM) turns on the trans control relay which supplies electrical power to the solenoid valve. Operating voltage is 12 volts (DC). The PCM controls the ground side of the solenoid using the governor pressure solenoid control circuit. GOVERNOR PRESSURE SENSOR The sensor output signal provides the necessary feedback to the PCM. This feedback is needed to adequately control governor pressure. GOVERNOR BODY AND TRANSFER PLATE The transfer plate channels line pressure to the solenoid valve through the governor body. It also channels governor pressure from the solenoid valve to the governor circuit. It is the solenoid valve that develops the necessary governor pressure. GOVERNOR PRESSURE CURVES LOW TRANSMISSION FLUID TEMPERATURE When the transmission fluid is cold the conventional governor can delay shifts, resulting in higher than normal shift speeds and harsh shifts. The electronically controlled low temperature governor pressure curve is higher than normal to make the transmission shift at normal speeds and sooner. The PCM uses a temperature sensor in the transmission oil sump to determine when low temperature governor pressure is needed. NORMAL OPERATION Normal operation is refined through the increased computing power of the PCM and through access to data on engine operating conditions provided by the PCM that were not available with the previous stand-alone electronic module. This facilitated the development of a load adaptive shift strategy - the ability to alter the shift schedule in response to vehicle load condition. One manifestation of this capability is grade "hunting" prevention - the ability of the transmission logic to delay an upshift on a grade if the engine does not have sufficient power to maintain speed in the higher gear. The 3-2 downshift and the potential for hunting between gears occurs with a heavily loaded vehicle or on steep grades. When hunting occurs, it is very objectionable because shifts are frequent and accompanied by large changes in noise and acceleration. WIDE OPEN THROTTLE OPERATION In wide-open throttle (WOT) mode, adaptive memory in the PCM assures that up-shifts occur at the preprogrammed optimum speed. WOT operation is determined from the throttle position sensor, which is also a part of the emission control system. The initial setting for the WOT upshift is below the optimum engine speed. As WOT shifts are repeated, the PCM learns the time required to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed. After each shift, the PCM adjusts the shift point until the optimum speed is reached. The PCM also considers vehicle loading, grade and engine performance changes due to high altitude in determining when to make WOT shifts. It does this by measuring vehicle and engine acceleration and then factoring in the shift time. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Description > Page 7887 TRANSFER CASE LOW RANGE OPERATION On four-wheel drive vehicles operating in low range, the engine can accelerate to its peak more rapidly than in Normal range, resulting in delayed shifts and undesirable engine "flare." The low range governor pressure curve is also higher than normal to initiate upshifts sooner. The PCM compares electronic vehicle speed signal used by the speedometer to the transmission output shaft speed signal to determine when the transfer case is in low range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal Governor: Service and Repair Removal REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter. 3. Disengage wire connectors from pressure sensor (1) and solenoid (2). 4. Remove screws holding pressure solenoid retainer (1) to governor body (2). 5. Separate solenoid retainer from governor. 6. Pull solenoid (1) from governor body (3). 7. Pull pressure sensor from governor body. 8. Remove bolts holding governor body to valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal > Page 7890 9. Separate governor body (1) from valve body. 10. Remove governor body gasket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal > Page 7891 Governor: Service and Repair Installation INSTALLATION Before installing the pressure sensor and solenoid in the governor body, replace o-ring seals, clean the gasket surfaces and replace gasket. 1. Place gasket (2) in position on back of governor body (1). 2. Place governor body in position on valve body. 3. Install bolts to hold governor body to valve body. 4. Lubricate o-ring on pressure sensor with transmission fluid. 5. Align pressure sensor to bore in governor body. 6. Push pressure sensor into governor body. 7. Lubricate o-ring (2), on pressure solenoid (1), with transmission fluid. 8. Align pressure solenoid (1) to bore in governor body (3). 9. Push solenoid into governor body. 10. Place solenoid retainer (1) in position on governor (2). 11. Install screws to hold pressure solenoid retainer to governor body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal > Page 7892 12. Engage wire connectors into pressure sensor (1) and solenoid (2). 13. Install transmission fluid pan and (new) filter. 14. Lower vehicle and road test to verify repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Description Overdrive Indicator Lamp: Description and Operation Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Description > Page 7898 Overdrive Indicator Lamp: Description and Operation Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, Refer to appropriate testing. For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 7903 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation > Description Transmission Mode Indicator - A/T: Description and Operation Description DESCRIPTION An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Each character appears in a blue-green color and at the same lighting level as the odometer information. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps are OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster general illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a PARADE mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation > Description > Page 7908 Transmission Mode Indicator - A/T: Description and Operation Operation OPERATION The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission type that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon an electronic selected gear message received from the Transmission Control Module (TCM) over the Controller Area Network (CAN) data bus. If the Transmission Range Sensor (TRS) mux circuit is open and no electronic selected gear messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the TRS. If the cluster is configured for an automatic transmission with a TRS input and detects a short to ground or an open in the TRS mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the TRS, then sends the proper message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles without a TCM, the EMIC continually monitors the hard wired TRS multiplexed input. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the EMIC, the CAN data bus or the electronic communication related to gear selector indicator operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description Overdrive Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > Description > Page 7914 Overdrive Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal Overdrive Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7917 Overdrive Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Description Overdrive Indicator Lamp: Description and Operation Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Description > Page 7922 Overdrive Indicator Lamp: Description and Operation Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, Refer to appropriate testing. For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 7926 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 7927 Overdrive Switch: Diagrams Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 7928 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 7929 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7932 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7933 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7934 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7935 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7936 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7937 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 7938 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7943 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7944 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7945 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7946 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7947 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7948 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7949 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7950 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7951 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7952 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7953 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7954 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7955 Pressure Regulating Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 7956 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7959 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7960 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7961 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7962 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7963 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7964 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7965 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7966 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7967 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7968 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7969 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7970 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7971 Pressure Regulating Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 7972 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description Pressure Regulating Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Description > Page 7975 Pressure Regulating Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal Pressure Regulating Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Removal > Page 7978 Pressure Regulating Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7988 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7989 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7995 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 7996 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 Control Module: Locations Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 7999 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 8000 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 8001 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 8002 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 8003 Control Module: Locations Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 8004 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 8005 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 8006 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 8007 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 Control Module: Diagrams Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 8010 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 8011 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 8012 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 8013 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 8014 Control Module: Diagrams Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 8015 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 8016 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 8017 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 8018 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 8021 On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 8022 Control Module: Description and Operation Transmission Control Module - Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 8023 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 8024 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 8025 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 8026 Some examples of TCM.indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations The Transmission Control Relay is not serviceable if equipped Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8040 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8041 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8044 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8045 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8046 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8047 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8048 Transmission Control System Relay: Connector Views Component ID: 246 Component : RELAY-TRANSMISSION Connector: Name : RELAY-TRANSMISSION Color : # of pins : 4 Pin Circuit Description 1 A916 16RD FUSED B(+) 2 T16 16YL TRANSMISSION CONTROL OUTPUT 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 Z420 18BK GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 68RFE Automatic Transmission Seals and Gaskets: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. On 4WD vehicles remove the transfer case from the transmission, on 2WD vehicles remove the propeller shaft. 2. Using a pry tool, remove the output shaft seal. Installation INSTALLATION NOTE: On the 2WD models use Seal Installer 8154 with Handle C-4171. 1. Clean the seal bore in the extension housing of any residue or particles remaining from the original seal. 2. Install new oil seal in the extension housing using Handle C-4171 (1) and Seal Installer 10020 (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 68RFE Automatic Transmission > Page 8055 Seals and Gaskets: Service and Repair 48RE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. 4. Remove old seal with a screw mounted in a slide hammer. Installation INSTALLATION 1. Place seal in position on overdrive housing. 2. Drive seal into overdrive housing with Seal Installer 8154 (1) or 9037 (1) if equipped with a dust boot and Handle C-4171. 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 68RFE Automatic Transmission > Page 8056 Seals and Gaskets: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Remove the transmission from the vehicle. See: Service and Repair/Removal and Replacement/AS68RC Automatic Transmission/Removal 2. Remove the torque converter from the transmission torque converter housing. See: Torque Converter/Service and Repair/AS68RC Automatic Transmission/Removal 3. Use a pry tool to remove oil pump seal. Installation INSTALLATION NOTE: Apply trans jell or petroleum jelly to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. 1. Clean and inspect oil pump seal seat. Then install seal using Converter Hub Seal Installer 9987. 2. Clean and inspect torque converter hub. If nicks, scratches or hub wear are found, torque converter replacement will be required. CAUTION: If the torque converter is being replaced, apply a light coating of grease to the crankshaft pilot hole. Also inspect the engine drive plate for cracks. If any cracks are found replace the drive plate. Do not attempt to repair a cracked drive plate. Always use new torque converter to drive plate bolts. 3. Apply a light film of MOPAR(R) AS68RC ATF oil to the torque converter hub and oil seal lips. Then install torque converter into transmission. Be sure that the hub lugs mesh with the front pump lugs when installing. See: Torque Converter/Service and Repair/AS68RC Automatic Transmission/Installation 4. Install the transmission into the vehicle. See: Service and Repair/Removal and Replacement/AS68RC Automatic Transmission/Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8061 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8062 Fluid Pressure Sensor/Switch: Diagrams Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8063 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 8066 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 8069 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8073 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8074 Overdrive Switch: Diagrams Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8075 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 8076 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8079 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8080 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8081 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8082 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8083 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8084 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8085 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description Shift Solenoid Position Sensor/Switch: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description > Page 8090 Shift Solenoid Position Sensor/Switch: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 545RFE PRESSURE SWITCH STATES: A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal Shift Solenoid Position Sensor/Switch: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal > Page 8093 Shift Solenoid Position Sensor/Switch: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8098 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8099 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8100 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8101 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8102 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8103 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8104 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8105 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8106 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8107 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8108 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8111 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8112 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8113 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8114 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8115 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8116 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8117 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8118 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8119 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8120 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8121 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8124 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8125 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8126 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 8127 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8130 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8131 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8132 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8133 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8138 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8139 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8140 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8141 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8142 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8143 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8144 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8145 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8146 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8147 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8148 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8149 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8150 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8151 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8152 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8153 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8154 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8155 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8156 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8157 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8158 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8159 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8160 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8161 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8162 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8163 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8164 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8165 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8166 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8167 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8168 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8169 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8170 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8171 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8172 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8173 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8174 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8177 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8178 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8179 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8180 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8181 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8182 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8183 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8184 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8185 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8186 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8187 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8188 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8189 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8190 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8191 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8192 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8193 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8194 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8195 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8196 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8197 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8198 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8199 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8200 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8201 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8202 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8203 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8204 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8205 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8206 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8207 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8208 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8209 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8210 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8211 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8212 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8213 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8216 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8217 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8220 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8221 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8222 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8223 INPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8227 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8228 Transmission Temperature Sensor/Switch: Diagrams Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8229 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description Transmission Temperature Sensor/Switch: Description and Operation Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 8232 Transmission Temperature Sensor/Switch: Description and Operation Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission Transmission Temperature Sensor/Switch: Service and Repair 48RE Automatic Transmission Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 8235 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 8236 Transmission Temperature Sensor/Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 8237 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 8238 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Component ID: 455 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Circuit Description 1 K32 18DB/YL BTSI SOLENOID CONTROL 2 Z101 18BK/VT GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8243 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8244 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8245 Shift Interlock Solenoid: Diagrams Component ID: 455 Component : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Connector: Name : SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK Color : BLACK # of pins : 2 Pin Circuit Description 1 K32 18DB/YL BTSI SOLENOID CONTROL 2 Z101 18BK/VT GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8246 Component Location - 42 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 8247 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid Shift Solenoid: Locations Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8252 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8253 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8254 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8255 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8256 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8257 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8258 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8259 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8260 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8261 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8262 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8263 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8264 Shift Solenoid: Locations Assembly-Transmission Solenoid/Pressure Switch Component ID: 20 Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH Color : LT. BROWN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T60 20YL/GY OD CONTROL 2 T59 20YL/LB UD CONTROL 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 4 T19 18YL/DB 2-4 CONTROL 5 T47 18YL/DG 2-4 PRESSURE SIGNAL 6 T9 20DG/TN OD PRESSURE SIGNAL 7 T20 20DG/WT L/R CONTROL 8-9-10 T50 20YL/TN L/R PRESSURE SIGNAL Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8265 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8266 Shift Solenoid: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Assembly-Transmission Solenoid > Page 8267 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid Shift Solenoid: Diagrams Assembly-Transmission Solenoid Component ID 15 Component ID: 15 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8270 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8271 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8272 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8273 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8274 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8275 Component ID 19 Component ID: 19 Component : ASSEMBLY-TRANSMISSION SOLENOID Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID Color : # of pins : 8 Qualifier : (RE) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8276 Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2 F856 18YL/PK 5 VOLT SUPPLY 3 K900 20DB/DG SENSOR GROUND 4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL 5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL 6 T9 18DG/TN 3-4 SOLENOID CONTROL 7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL 8 T54 18DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8277 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C1 Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T806 20DG/VT PRESSURE SIGNAL 7 2 T804 20YL/DB PRESSURE SIGNAL 5 3 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 4 T817 20YL/BR LINEAR 3 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8278 5 T813 20DG/LG LINEAR 1 CONTROL 6 T807 20DG/WT PRESSURE SIGNAL 8 7 T803 20DG/BR PRESSURE SIGNAL 4 8 T820 20YL/WT TEMPERATURE SENSOR GROUND 9 T816 20YL/PK LINEAR 3 GROUND 10 T812 20DG/TN LINEAR 1 GROUND Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8279 Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID C2 Color : # of pins : 12 Qualifier : (RC) Pin Circuit Description 1 T800 20DG/BR PRESSURE SIGNAL 1 2 T805 20DG/OR PRESSURE SIGNAL 6 3 T809 20DG/YL SHIFT 2 CONTROL 4 T811 20DG/LB SHIFT 4 CONTROL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8280 5 T818 20YL/OR LINEAR 4 GROUND 6 T814 20YL/BR LINEAR 2 GROUND 7 T801 20DG/RD PRESSURE SIGNAL 2 8 T802 20DG/PK PRESSURE SIGNAL 3 9 T810 20DG/DB SHIFT 3 CONTROL 10 T808 20DG/GY SHIFT 1 CONTROL 11 T821 20YL/GY LINEAR 4 CONTROL 12 T815 20YL/RD LINEAR 2 CONTROL Component Location - 20 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8281 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8282 Shift Solenoid: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Assembly-Transmission Solenoid > Page 8283 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > Description Shift Solenoid: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > Description > Page 8286 Shift Solenoid: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 3rd gear and reverse limp-in operation. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Removal Shift Solenoid: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8289 Shift Solenoid: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Shifter A/T: Description and Operation 42RLE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual second (2) - Manual low (1) Operation OPERATION MANUAL LOW (1) range provides FIRST gear only. Overrun braking is also provided in this range. MANUAL SECOND (2) range provides FIRST and SECOND gear only. DRIVE range provides FIRST, SECOND, THIRD and OVERDRIVE FOURTH gear ranges. The shift into OVERDRIVE FOURTH gear range occurs only after the transmission has completed the shift into D THIRD gear range. No further movement of the shift mechanism is required to complete the 3-4 shift. The FOURTH gear upshift occurs automatically when the overdrive selector switch is in the ON position. An upshift to FOURTH gear may not occur or may be delayed in some of the possible shift schedules. See: Control Module/Description and Operation/Transmission Control Module Operation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 8294 Shifter A/T: Description and Operation 545RFE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual second (2) - Manual low (1) Operation OPERATION MANUAL LOW (1) range provides first gear only. Maximum engine braking is also provided in this range. MANUAL SECOND (2) range provides first and second gear only. DRIVE range provides FIRST, SECOND, THIRD, OVERDRIVE FOURTH, and OVERDRIVE FIFTH gear ranges. The shift into OVERDRIVE FOURTH and FIFTH gear ranges occurs only after the transmission has completed the shift into D THIRD gear range. No further movement of the shift mechanism is required to complete the 3-4 or 4-5 shifts. The FOURTH and FIFTH gear upshifts occur automatically unless the Tow/Haul or OD Off mode is enabled. No upshift to FOURTH or FIFTH gears will occur if any of the following are true: - The transmission fluid temperature is below 10° C (50° F) or above 121° C (250° F). - The shift to THIRD is not yet complete. - Vehicle speed is too low for the 3-4 or 4-5 shifts to occur. Upshifts into FOURTH or FIFTH will be delayed when the transmission fluid temperature is below 4.5° C (40° F) or above 115.5° C (240° F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 8295 Shifter A/T: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides four shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) Operation OPERATION Drive range provides underdrive FIRST, SECOND and THIRD gears, direct FOURTH gear and overdrive FIFTH and SIXTH gears. The shift into overdrive FIFTH and SIXTH gear occurs only after the transmission has completed the shift into FOURTH gear. No other movement of the shift mechanism is required to complete the 4-5 or 5-6 gear shifts. The FOURTH and FIFTH gear upshift occurs automatically unless the Tow/Haul mode is enabled. Upshifts into both overdrive gears, FIFTH and SIXTH, will be delayed when the transmission fluid temperature is below 4.5° C (40° F) or above 115.5° C (240° F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 8296 Shifter A/T: Description and Operation 48RE Automatic Transmission Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - PARK (P) - REVERSE (R) - NEUTRAL (N) - DRIVE (D) - Manual SECOND (2) - Manual LOW (1) Operation OPERATION Manual LOW (1) range provides first gear only. Overrun braking is also provided in this range. Manual SECOND (2) range provides first and second gear only. DRIVE range provides first, second, third, and overdrive fourth gear ranges. The shift into overdrive fourth gear range occurs only after the transmission has completed the shift into D third gear range. No further movement of the shift mechanism is required to complete the 3-4 shift. The fourth gear upshift occurs automatically when the overdrive selector switch is in the ON position. No upshift to fourth gear will occur if any of the following are true: - The transmission fluid temperature is below 10° C (50° F) or above 121° C (250° F). - The shift to third is not yet complete. - Vehicle speed is too low for the 3-4 shift to occur. - Battery temperature is below -5° C (23° F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 8297 Shifter A/T: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The gear shift mechanism provides seven shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual Third (3) - Manual second (2) - Manual low (1) Operation OPERATION MANUAL LOW (1) range provides first gear only. Maximum engine braking is also provided in this range. MANUAL SECOND (2) range provides first and second gear only. MANUAL THIRD range provides first, second and third gear only. DRIVE range provides FIRST, SECOND, THIRD, FOURTH, OVERDRIVE FIFTH, OVERDRIVE SIXTH gear ranges. The shift into OVERDRIVE FOURTH and FIFTH gear ranges occurs only after the transmission has completed the shift into D THIRD gear range. The SIXTH gear upshifts occur automatically unless the Tow/Haul or OD Off mode is enabled. No upshift to FIFTH or SIXTH gears will occur if any of the following are true: - The transmission fluid temperature is below 5° C (41° F). - The shift to Fourth is not yet complete. - Vehicle speed is too low for the 4-5 or 5-6 shifts to occur. - Transfer case is in low range. Upshifts into FOURTH or FIFTH will be delayed when the transmission fluid temperature is below 4.5° C (40° F) or above 115.5° C (240° F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission Shift Cable: Testing and Inspection 42RLE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 8303 Shift Cable: Testing and Inspection 545RFE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 8304 Shift Cable: Testing and Inspection 68RFE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 8305 Shift Cable: Testing and Inspection 48RE Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 8306 Shift Cable: Testing and Inspection AS68RC Automatic Transmission DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 68RFE Automatic Transmission Shift Cable: Adjustments 68RFE Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 68RFE Automatic Transmission > Page 8309 Shift Cable: Adjustments 48RE Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 68RFE Automatic Transmission > Page 8310 Shift Cable: Adjustments AS68RC Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Shift Cable: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8313 Gearshift Cable at Steering Column 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. Gearshift Cable at Steering Column 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8314 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism See: Shift Interlock/Adjustments/42RLE Automatic Transmission . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8315 Shift Cable: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8316 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable See: Shift Interlock/Adjustments/42RLE Automatic Transmission . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8317 Shift Cable: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8318 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable See: Adjustments/48RE Automatic Transmissionand BTSI mechanism See: Shift Interlock/Adjustments/42RLE Automatic Transmission . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8319 Shift Cable: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8320 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable See: Adjustments/68RFE Automatic Transmissionand BTSI mechanism See: Shift Interlock/Adjustments/42RLE Automatic Transmission . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8321 Shift Cable: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disconnect the shift cable ball socket (3) at transmission manual shift lever (4) and pull shift cable out of mounting bracket (1). 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8322 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 8323 6. Route the gearshift cable through the shift cable mounting bracket (1) and secure the cable by snapping the cable retaining ears into the bracket and by snapping the shift cable ball socket (3) onto the manual shift lever (4) ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable See: Adjustments/AS68RC Automatic Transmissionand BTSI mechanism See: Shift Interlock/Adjustments/AS68RC Automatic Transmission . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description Shift Solenoid Position Sensor/Switch: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description > Page 8328 Shift Solenoid Position Sensor/Switch: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 545RFE PRESSURE SWITCH STATES: A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal Shift Solenoid Position Sensor/Switch: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal > Page 8331 Shift Solenoid Position Sensor/Switch: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 8336 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation Throttle Valve Solenoid: Description and Operation DESCRIPTION On vehicles equipped with a Cummins diesel engine, the transmission throttle valve cable has been replace by the transmission throttle valve actuator (TTVA). The TTVA consists of an electric DC motor, two potentiometers, and a gear drive system. The TTVA is mechanically connected to the transmission throttle valve in the valve body by the "D" shaped opening in the bottom of the TTVA shaft. Changes in the TTVA position are therefore transferred to the throttle valve and cause changes in the transmission throttle pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Description and Operation > Page 8341 Throttle Valve Solenoid: Adjustments ADJUSTMENT The Transmission Throttle Valve Actuator (TTVA) does not require any mechanical adjustments. All changes in throttle valve position are controlled by the Engine Control Module (ECM). The TTVA does require an initialization period after the actuator has been removed or replaced. After the actuator has been removed or replaced, move the ignition to the ON position for thirty (30) seconds. This will allow the ECM sufficient time to perform the internal calibration procedures to learn the TTVA's current "zero" position. Once this is done, check the ECM for diagnostic trouble codes (DTCs). If no DTCs are set relating to the TTVA, the TTVA is fully calibrated and ready for use. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal Throttle Valve Solenoid: Service and Repair Removal REMOVAL 1. Remove the bolts (2) holding the transmission throttle valve actuator (TTVA) (1) to the transmission case. 2. Allow the TTVA (1) to rotate clockwise away from the transmission. 3. Remove the wiring connector (2) from the TTVA (1). 4. Lift the TTVA (1) straight upward and off the throttle valve shaft (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve Solenoid, A/T > Component Information > Service and Repair > Removal > Page 8344 Throttle Valve Solenoid: Service and Repair Installation INSTALLATION 1. Position the transmission throttle valve actuator (TTVA) (1) over the throttle valve shaft (3). 2. Align the D-shaped opening in the bottom of the TTVA to the throttle valve shaft and install the TTVA onto the shaft. 3. Install the wiring connector (2) to the TTVA (1). 4. Rotate the TTVA (1) to the transmission case and install the bolts (2) to hold the TTVA to the transmission. 5. Tighten the bolts to 8.5 Nm (75 in.lbs.). 6. Initialize the TTVA See: Adjustments . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation Throttle Valve Cable/Linkage: Description and Operation DESCRIPTION Transmission throttle valve cable (1) adjustment is extremely important to proper operation. This adjustment positions the throttle valve, which controls shift speed, quality, and part-throttle downshift sensitivity. If cable setting is too loose, early shifts and slippage between shifts may occur. If the setting is too tight, shifts may be delayed and part throttle downshifts may be very sensitive. The transmission throttle valve is operated by a cam on the throttle lever. The throttle lever is operated by an adjustable cable (3). The cable is attached to an arm mounted on the throttle lever shaft. A retaining clip (2) at the engine-end of the cable is removed to provide for cable adjustment. The retaining clip is then installed back onto the throttle valve cable to lock in the adjustment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > Page 8348 Throttle Valve Cable/Linkage: Adjustments ADJUSTMENTS - THROTTLE VALVE CABLE A correctly adjusted throttle valve cable (1) will cause the throttle lever on the transmission to move simultaneously with the throttle body lever (3) from the idle position. Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of, or lag behind the lever on the throttle body. ADJUSTMENT VERIFICATION 1. Turn ignition key to OFF position. 2. Remove air cleaner. 3. Verify that lever on throttle body is at curb idle position. Then verify that the transmission throttle lever is also at idle (fully forward) position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > Page 8349 4. Slide cable off attachment stud on throttle body lever. 5. Compare position (B) of cable end to attachment stud on throttle body lever: - Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 in.) in either direction (B). - If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in Throttle Valve Cable Adjustment procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body. - If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. - If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. ADJUSTMENT PROCEDURE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Description and Operation > Page 8350 1. Turn ignition switch to OFF position. 2. Remove air cleaner if necessary. 3. Disconnect cable end (3) from attachment stud on throttle lever (1). Carefully slide cable off stud. Do not pry or pull cable off. 4. Verify that transmission throttle lever is in fully closed position. Then be sure lever on throttle body is at curb idle position. 5. Pry the T.V. cable lock (A) into the UP position. This will unlock the cable and allow for readjustment. 6. Apply just enough tension on the T.V. cable (B) to remove any slack in the cable. Pulling too tight will cause the T.V. lever on the transmission to move out of its idle position, which will result in an incorrect T.V. cable adjustment. Slide the sheath of the T.V. cable (D) back and forth until the centerlines of the T.V. cable end (B) and the throttle bell crank lever (C) are aligned within one millimeter (1mm). 7. While holding the T.V. cable in the set position push the T.V. cable lock (A) into the down position. This will lock the present T.V. cable adjustment. NOTE: Be sure that as the cable is pulled forward and centered on the throttle lever stud, the cable housing moves smoothly with the cable. Due to the angle at which the cable housing enters the spring housing, the cable housing may bind slightly and create an incorrect adjustment. 8. Reconnect the T.V. cable (B) to the throttle bellcrank lever (C). 9. Check cable adjustment. Verify transmission throttle lever and lever on throttle body move simultaneously. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed Torque Converter: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (4), an overrunning clutch, an impeller (2), and an electronically applied converter clutch (6). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8355 Impeller The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8356 Turbine The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator contains an over-running clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8357 The stator (1) is located between the impeller (2) and turbine (4) within the torque converter case. TORQUE CONVERTER CLUTCH (TCC) The TCC was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston (6) was added to the turbine (5), and a friction material (7) was added to the inside of the front cover (1) to provide this mechanical lock-up. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8358 Torque Converter Fluid Operation The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in a direction that would tend to slow it down. STATOR Stator Operation Torque multiplication is achieved by locking the stator's over-running clutch to its shaft. Under stall conditions the turbine is stationary and the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the overrunning Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8359 clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades (1) and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 1.75:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) The torque converter clutch is hydraulically applied or released when fluid is feed or vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch engages in FOURTH gear, and in THIRD gear under various conditions, such as when the O/D switch is OFF, or when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch can also be engaged in the MANUAL SECOND gear position if high transmission temperatures are sensed by the PCM. The torque converter clutch may disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8360 Torque Converter: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (2), an overrunning clutch, an impeller (5), and an electronically applied converter clutch (6). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub (3) drives the transmission oil (fluid) pump and contains an o-ring seal (4) to better control oil flow. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8361 The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8362 The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator (1) is located between the impeller (2) and the turbine (4) within the torque converter case. The stator contains an over-running clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8363 The TCC was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller (3) and turbine (5) were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston (6) with friction material (7) was added to the turbine assembly (5) to provide this mechanical lock-up. In order to reduce heat build-up in the transmission and buffer the powertrain against torsional vibrations, the TCM can duty cycle the L/R-CC Solenoid to achieve a smooth application of the torque converter clutch. This function, referred to as Electronically Modulated Converter Clutch (EMCC) can occur at various times depending on the following variables: - Shift lever position - Current gear range - Transmission fluid temperature - Engine coolant temperature - Input speed - Throttle angle - Engine speed Operation OPERATION The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8364 TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft. Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 1.75:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The clutch can be engaged in all gear ranges except first depending on the Tow/Haul and ERS status. In normal operation, the clutch will engage after the shift to fourth gear. If the Tow/Haul mode is enabled, the clutch will engage after the shift to third (direct) gear. The TCM controls the torque converter clutch via the L/R-CC Solenoid. There are four TCC operational modes: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8365 - No EMCC - Partial EMCC - Full EMCC - Gradual EMCC Release NO EMCC Under No EMCC conditions, the L/R Solenoid is OFF. There are several conditions that can result in NO EMCC operations. No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need for EMCC under current driving conditions. PARTIAL EMCC Partial EMCC operation modulates the L/R Solenoid (duty cycle) to obtain partial torque converter clutch application. Partial EMCC operation is maintained until Full EMCC is called for and actuated. During Partial EMCC some slip does occur. Partial EMCC will usually occur at low speeds, low load and light throttle situations. FULL EMCC During Full EMCC operation, the TCM increases the L/R Solenoid duty cycle to full ON after Partial EMCC control brings the engine speed within the desired slip range of transmission input speed relative to engine rpm. GRADUAL EMCC RELEASE This operation is to soften the change from Full or Partial EMCC to No EMCC. This is done at mid-throttle by slowly decreasing the L/R Solenoid duty cycle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8366 Torque Converter: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an lock-up damper (1), lock-up piston (3 ), pump impeller (4), turbine runner (5), stator (6), and one-way clutch (7). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8367 Impeller The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8368 Turbine The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8369 The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator (1) is located between the impeller (2) and the turbine (4) within the torque converter case. The stator contains an one-way clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. Torque Converter Solenoid In order to reduce heat build-up in the transmission and buffer the powertrain against torsional vibrations, the TCM can duty cycle the Torque Converter Solenoid to achieve a smooth application of the torque converter clutch. This function can occur at various times depending on the following variables: - Shift lever position - Current gear range - Transmission fluid temperature - Engine coolant temperature - Input speed - Throttle angle - Engine speed Operation OPERATION The torque converter transmits engine torque to the transmission. When it is not locked up, it transmits the torque by means of oil. When it is locked up, it transmits the torque by means of the lockup piston. The lockup damper is designed to soften the impact as the torque converter locks up. The torque converter is a 3-element, single-stage, 2-phase type. The term 'single-stage' indicates that there is 1 turbine runner (output element). The term '2-phase' indicates that the mechanism works as a torque converter when the turbine runner is turning slowly relative to the pump impeller and as a fluid coupling when the turbine runner is turning quickly relative to the pump impeller. TORQUE CONVERTER NOT LOCKED UP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8370 The torque converter activation pressure is not supplied between the converter front cover and lockup piston via passage (3). The lockup clutch (1) and the plate (2) are therefore disengaged and the lockup function is inactive. TORQUE CONVERTER LOCKED UP The torque converter activation pressure is supplied between the converter front cover and lockup piston via passage (3). The lockup clutch (1) and the plate (2) are therefore engaged and the lockup function is active. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's one-way clutch to its shaft. Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the one-way clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8371 Stator Operation TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The clutch can be engaged in second, third, fourth, fifth and, sixth gear ranges. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed Torque Converter: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Installation INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be 19mm (0.75 in.) to the rear of the straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed > Page 8374 Torque Converter: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Remove transmission and torque converter from vehicle. See: Service and Repair/Removal and Replacement/68RFE Automatic Transmission/Removal 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Installation INSTALLATION NOTE: Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 800/1000 grit paper or crocus cloth if necessary. Verify that the converter hub o-ring is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or converter hub o-ring while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be at least 25 mm (1in.) to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. See: Service and Repair/Removal and Replacement/68RFE Automatic Transmission/Installation 9. Fill the transmission with the recommended fluid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed > Page 8375 Torque Converter: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Remove transmission from vehicle. See: Service and Repair/Removal and Replacement/AS68RC Automatic Transmission/Removal 2. Place a suitable drain pan under the converter housing end of the transmission. WARNING: Be certain the transmission is secure when removing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal. TC REMOVAL 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. Installation INSTALLATION NOTE: Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 800/10000 grit paper or crocus cloth if necessary. Verify that the oil pump seal is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. TC REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 48RE (A-618) 4 Speed > Page 8376 1. Lubricate oil pump seal lip and input shaft seal rings with MOPAR(R) AS68RC ATF. WARNING: Be certain the transmission is secure when installing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or input shaft seal rings while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Install the transmission into the vehicle. See: Service and Repair/Removal and Replacement/AS68RC Automatic Transmission/Installation 7. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be at least 28.2 mm (1.12 in.) to rear of straightedge when converter is fully seated. 8. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 9. Install the transmission in the vehicle. See: Service and Repair/Removal and Replacement/AS68RC Automatic Transmission/Installation 10. Fill the transmission with the recommended fluid. See: Service and Repair/Procedures/AS68RC Automatic Transmission/Transmission Fill - AS68RC Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Description Torque Converter Check Valve: Description and Operation Description DIESEL ENGINE The converter drainback check valve is located in the in the TOC pressure - supply line, between the engine mounted TOC and the air to oil TOC. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Description > Page 8381 Torque Converter Check Valve: Description and Operation Operation DIESEL ENGINE The valve prevents fluid from draining from the converter into the cooler and lines when the vehicle is shut down for lengthy periods. Production valves have pipe thread on one end, while the opposite end is threaded for a flare fitting, and are threaded into the oil cooler mounted on the side of the engine. All valves have an arrow (or similar mark) to indicate direction of flow through the valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Description and Operation > Page 8382 Torque Converter Check Valve: Service and Repair DIESEL ENGINE The converter drainback check valve is located in the in the TOC pressure - supply line, between the engine mounted transmission oil cooler and the air to oil transmission oil cooler. The valve prevents fluid drainback when the vehicle is parked for lengthy periods. The valve check ball is spring loaded and has an opening pressure of approximately 2 psi. The valve is serviced as an assembly; it is not repairable. Do not clean the valve if restricted, or contaminated by sludge, or debris. If the valve fails, or if a transmission malfunction occurs that generates significant amounts of sludge and/or clutch particles and metal shavings, the valve must be replaced. If the valve is restricted, installed backwards, or in the wrong line, it will cause an transmission overheating condition and possible transmission failure. CAUTION: The drainback valve is a one-way flow device. It must be properly oriented in terms of flow direction for the cooler to function properly. The valve must be installed in the pressure line. Otherwise flow will be blocked and would cause an transmission overheating condition and eventual transmission failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations The Transmission Control Relay is not serviceable if equipped Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8388 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8389 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8390 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8401 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8402 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8403 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8404 Transmission Control System Relay: Connector Views Component ID: 246 Component : RELAY-TRANSMISSION Connector: Name : RELAY-TRANSMISSION Color : # of pins : 4 Pin Circuit Description 1 A916 16RD FUSED B(+) 2 T16 16YL TRANSMISSION CONTROL OUTPUT 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 Z420 18BK GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > All Vehicles Transmission Cooler: Description and Operation All Vehicles ALL VEHICLES An air-to-oil transmission oil cooler is standard on all engine packages. The transmission oil cooler is mounted to the front of the radiator above the power steering cooler and Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > All Vehicles > Page 8411 Transmission Cooler: Description and Operation Diesel DIESEL The 5.9L diesel models equipped with an automatic transmission are equipped with a water-to-oil cooler and a separate air-to-oil cooler. Both coolers are supplied as standard equipment on diesel engine powered models when equipped with an automatic transmission. The water-to-oil transmission oil cooler is mounted to a bracket on the intake side of the engine. The 6.7L model diesel with automatic transmission is equipped with an air-to-oil cooler only. This cooler is located in front of the radiator. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures Transmission Cooler: Procedures TRANSMISSION COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY DISCONNECT 1. Remove dust cap by pulling it straight back off of quick connect fitting 2. Place disconnect tool Special Tool 8875A onto transmission cooler line with the fingers of the tool facing the quick connect fitting. 3. Slide disconnect tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting. 4. Rotate the disconnect tool 60° to expand the retaining clip. 5. While holding the disconnect tool against the quick connect fitting, pull back on the transmission cooler line to remove. CONNECT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 8414 1. Align transmission cooler line with quick connect fitting while pushing straight into the fitting. 2. Push in on transmission cooler line until a "click" is heard or felt. 3. Slide dust cap down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap will only snap over quick connect fitting when the transmission cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step 2. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 8415 Transmission Cooler: Removal and Replacement Air To Oil Cooler - Diesel AIR TO OIL COOLER - DIESEL 1. Remove Charge Air Cooler See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Removal . 2. Place a drain pan under the oil cooler. 3. Raise the vehicle. 4. Disconnect the oil cooler quick-connect fittings from the transmission lines See: Procedures . 5. Remove the charge air cooler-to-oil cooler bolt. 6. Remove two mounting nuts. 7. Remove the oil cooler and line assembly towards the front of vehicle. Cooler must be rotated and tilted into position while removing. Water To Oil Cooler REMOVAL - WATER TO OIL COOLER CAUTION: If a leak should occur in the water-to-oil cooler mounted to the side of the engine block, engine coolant may become mixed with transmission fluid. Transmission fluid may also enter engine cooling system. Both cooling system and transmission should be drained and inspected in case of oil cooler leakage. 1. Disconnect both battery negative cables. 2. Remove starter . 3. Drain cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 4. Disconnect coolant lines from cooler. NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler. 5. Disconnect transmission oil lines from cooler. Plug cooler lines to prevent oil leakage. 6. Remove cooler bracket to transmission adapter bolt. 7. Remove wire harness push in clip at bottom of coolant bracket. 8. Remove wire harness push in clip at bottom of coolant bracket. 9. Remove two cooler bracket to block bolts. 10. Remove cooler assembly from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 8416 Air To Oil Cooler - Diesel AIR TO OIL COOLER - DIESEL 1. Carefully position the oil cooler assembly to the vehicle. 2. Install two nuts and one bolt. Tighten to 11 Nm (95 in. lbs.) torque. 3. Connect the quick-connect fittings to the transmission cooler lines See: Procedures . 4. Install Charge Air Cooler See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Service and Repair/Installation . 5. Start the engine and check all fittings for leaks. 6. Check the fluid level in the automatic transmission. Water-To-Oil Cooler INSTALLATION - WATER-TO-OIL COOLER Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 8417 1. Position oil cooler on cylinder block. 2. Install 2 capscrews to cylinder block finger tight. 3. Install capscrews at the transmission adapter. Torque bolt to 24 Nm (18 ft. lbs.) 4. Tighten lower mounting bolt to cooler at the cylinder block. Tighten to 77 Nm (57 ft. lbs.). NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler. 5. Tighten upper mounting bolt to cooler at cylinder block to 24 N.m (18 ft. lbs). 6. Install wire harness push in clip at bottom of cooler bracket. 7. Install starter motor . 8. Connect battery negative cables. 9. Fill cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 10. Check transmission oil level and fill as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Description and Operation > Description Transmission Mode Indicator - A/T: Description and Operation Description DESCRIPTION An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Each character appears in a blue-green color and at the same lighting level as the odometer information. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps are OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster general illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a PARADE mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Description and Operation > Description > Page 8422 Transmission Mode Indicator - A/T: Description and Operation Operation OPERATION The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission type that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon an electronic selected gear message received from the Transmission Control Module (TCM) over the Controller Area Network (CAN) data bus. If the Transmission Range Sensor (TRS) mux circuit is open and no electronic selected gear messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the TRS. If the cluster is configured for an automatic transmission with a TRS input and detects a short to ground or an open in the TRS mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the TRS, then sends the proper message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles without a TCM, the EMIC continually monitors the hard wired TRS multiplexed input. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the EMIC, the CAN data bus or the electronic communication related to gear selector indicator operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8427 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8428 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8429 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8430 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8431 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8432 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8433 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8434 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8435 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8436 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 8437 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8440 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8441 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8442 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8443 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8444 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8445 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8446 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8447 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8448 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8449 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 8450 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8453 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8454 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8455 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 8456 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8459 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8460 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8461 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 8462 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8467 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8468 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8469 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8470 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8471 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8472 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8473 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8474 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8475 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8476 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8477 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8478 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8479 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8480 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8481 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8482 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8483 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8484 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8485 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8486 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8487 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8488 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8489 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8490 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8491 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8492 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8493 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8494 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8495 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8496 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8497 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8498 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8499 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8500 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8501 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8502 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 8503 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8506 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8507 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8508 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8509 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8510 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8511 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8512 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8513 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8514 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8515 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8516 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8517 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8518 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8519 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8520 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8521 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8522 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8523 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8524 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8525 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8526 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8527 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8528 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8529 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8530 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8531 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8532 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8533 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8534 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8535 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8536 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8537 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8538 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8539 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8540 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8541 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 8542 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8545 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8546 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8549 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8550 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8551 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 8552 INPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8556 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8557 Transmission Temperature Sensor/Switch: Diagrams Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 8558 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description Transmission Temperature Sensor/Switch: Description and Operation Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 8561 Transmission Temperature Sensor/Switch: Description and Operation Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission Transmission Temperature Sensor/Switch: Service and Repair 48RE Automatic Transmission Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 8564 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 8565 Transmission Temperature Sensor/Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 8566 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 8567 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Valve Body: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The valve body consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body contains the following components. By adjusting the spring pressure acting on the regulator valve, transmission line pressure can be adjusted. Upper Housing Control Valve Locations - Regulator valve (2) - Switch valve (3) - Regulator valve spring (4) - Kickdown valve (5) - Kickdown detent (6) - Throttle valve and spring (7) - Manual valve (8) - 1-2 Governor plug (9) - Throttle pressure plug (11) - 2-3 Governor plug (12) - Shuttle valve primary spring (13) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8572 Shuttle and Boost Valve Locations - Boost Valve (3) - Boost valve plug (4) - Shuttle valve (9) - Shuttle valve throttle plug (12) Upper Housing Shift Valve and Pressure Plug Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8573 - 1-2 shift valve (2) - 1-2 control valve - 2-3 shift valve - 2-3 throttle plug - Throttle pressure plug - Limit valve and spring Lower Housing Shift Valves and Springs - 3-4 shift valve - 3-4 timing valve - 3-4 quick fill valve - 3-4 accumulator - Converter clutch lock-up valve - Converter clutch lock-up timing valve Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8574 Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. CHECK BALLS REGULATOR VALVE Regulator Valve in Park Position The pressure regulator valve is needed to control the hydraulic pressure within the system and reduce the amount of heat produced in the fluid. The pressure regulator valve is located in the valve body near the manual valve. The pressure regulator valve train controls the maximum pressure in the lines by metering the dumping of fluid back into the sump. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the left. This closes a dump (vent) that is used to lower pressure. The closing of the dump will cause the oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the right, opening the dump and lowering oil pressure. The result is spring pressure working against oil pressure to maintain the oil at specific pressures. With the engine running, fluid flows from the pump to the pressure regulator valve, manual valve, and the interconnected circuits. As fluid is sent through passages to the regulator valve, the pressure pushes the valve to the right against the large spring. It is also sent to the reaction areas on the left side of the throttle pressure plug and the line pressure plug. With the gear selector in the PARK position, fluid recirculates through the regulator and manual valves back to the sump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8575 Regulator Valve in Neutral Position Meanwhile, the torque converter is filled slowly. In all other gear positions, fluid flows between two right side lands to the switch valve and torque converter. At low pump speeds, the flow is controlled by the pressure valve groove to reduce pressure to the torque converter. After the torque converter and switch valve fill with fluid, the switch valve becomes the controlling metering device for torque converter pressure. The regulator valve then begins to control the line pressure for the other transmission circuits. The balance of the fluid pressure pushing the valve to the right and the spring pressure pushing to the left determines the size of the metering passage at land #2 (land #1 being at the far right of the valve in the diagram). As fluid leaks past the land, it moves into a groove connected to the filter or sump. As the land meters the fluid to the sump, it causes the pressure to reduce and the spring decreases the size of the metering passage. When the size of the metering passage is reduced, the pressure rises again and the size of the land is increased again. Pressure is regulated by this constant balance of hydraulic and spring pressure. Regulator Valve in Drive Position The metering at land #2 establishes the line pressure throughout the transmission. It is varied according to changes in throttle position and the transmission's internal condition within a range of 57-94 psi (except in REVERSE). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8576 Regulator Valve in Reverse Position The regulated line pressure in REVERSE is held at much higher pressures than in the other gear positions: 145-280 psi. The higher pressure for REVERSE is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land #4. With this pressure blocked, there is less area for pressure to act on to balance the force of the spring on the right. This allows line pressure to push the valve train to the right, reducing the amount of fluid returned to the pump's inlet, increasing line pressure. KICKDOWN VALVE Kickdown Valve - Wide Open Throttle When the throttle valve is as far over to the left as it can go, the maximum line pressure possible will enter the throttle pressure circuit. In this case, throttle pressure will equal line pressure. With the kickdown valve pushed into the bore as far as it will go, fluid initially flows through the annular Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8577 groove of the 2-3 shift valve (which will be in the direct drive position to the right). After passing the annular groove, the fluid is routed to the spring end of the 2-3 shift valve. Fluid pressure reacting on the area of land #1 overcomes governor pressure, downshifting the 2-3 shift valve into the kickdown, or second gear stage of operation. The valve is held in the kickdown position by throttle pressure routed from a seated check ball (#2). Again, if vehicle speed is low enough, throttle pressure will also push the 1-2 shift valve left to seat its governor plug, and downshift to drive breakaway. KICKDOWN LIMIT VALVE Kickdown Limit Valve - Low Speeds The purpose of the limit valve is to prevent a 3-2 downshift at higher speeds when a part-throttle downshift is not desirable. At these higher speeds only a full throttle 3-2 downshift will occur. At low road speeds the limit valve does not come into play and does not affect the downshifts. Kickdown Limit Valve - High Speeds As the vehicle's speed increases, the governor pressure also increases. The increased governor pressure acts on the reaction area of the bottom land of the limit valve overcoming the spring force trying to push the valve toward the bottom of its bore. This pushes the valve upward against the spring and bottoms the valve against the top of the housing. With the valve bottomed against the housing, the throttle pressure supplied to the valve will be closed off by the bottom land of the limit valve. When the supply of throttle pressure has been shut off, the 3-2 part throttle downshift plug becomes inoperative, because no pressure is acting on its reaction area. 1-2 SHIFT VALVE 1-2 Shift Valve - Before Shift Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8578 The 1-2 shift valve assembly, or mechanism, consists of: the 1-2 shift valve, governor plug, and a spring on the end of the valve. After the manual valve has been placed into a forward gear range, line pressure is directed to the 1-2 shift valve. As the throttle is depressed, throttle pressure is applied to the right side of the 1-2 shift valve assembly. With throttle pressure applied to the right side of the valve, there is now both spring pressure and throttle pressure acting on the valve, holding it against the governor plug. As the vehicle begins to move and build speed, governor pressure is created and is applied to the left of the valve at the governor plug. 1-2 Shift Valve - After Shift When governor pressure builds to a point where it can overcome the combined force of the spring and throttle pressure on the other side of the valve, the valve will begin to move over to the right. As the valve moves to the right, the middle land of the valve will close off the circuit supplying the throttle pressure to the right side of the valve. When the throttle pressure is closed off, the valve will move even farther to the right, allowing line pressure to enter another circuit and energize the front servo, applying the front band. The governor plug serves a dual purpose: - It allows the shift valves to move either left or right, allowing both upshifts and downshifts. - When in a manual selection position, it will be hydraulically "blocked" into position so no upshift can occur. The physical blocking of the upshift while in the manual "1" position is accomplished by the directing of line pressure between both lands of the governor plug. The line pressure reacts against the larger land of the plug, pushing the plug back against the end plate overcoming governor pressure. With the combination of the line pressure and spring pressure, the valve cannot move, preventing any upshift. 1-2 SHIFT CONTROL VALVE 1-2 Shift Control Valve It contains a valve with four lands and a spring. It is used as both a "relay" and "balanced" valve. The valve has two specific operations: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8579 - Aid in quality of the 1-2 upshift. - Aid in the quality and timing of the 3-2 kickdown ranges. When the manual valve is set to the DRIVE position and the transmission is in the first or second gear range, 1-2 shift control or "modulated throttle pressure" is supplied to the middle of the accumulator piston by the 1-2 shift control valve. During the 1-2 upshift, this pressure is used to control the kickdown servo apply pressure that is needed to apply the kickdown and accumulator pistons. Thus, the 1-2 shift point is "cushioned" and the quality is improved. During a WOT kickdown, kickdown pressure is applied between the kickdown valve and the 1-2 shift control valve. This additional pressure is directed to the 1-2 shift control's spring cavity, adding to the spring load on the valve. The result of this increased "modulated" throttle pressure is a firmer WOT upshift. 2-3 SHIFT VALVE 2-3 Shift Valve - Before Shift The 2-3 shift valve mechanism consists of the 2-3 shift valve, governor plug and spring, and a throttle plug. After the 1-2 shift valve has completed its operation and applied the front band, line pressure is directed to the 2-3 shift valve through the connecting passages from the 1-2 shift valve. The line pressure will then dead-end at land #2 until the 2-3 valve is ready to make its shift. Now that the vehicle is in motion and under acceleration, there is throttle pressure being applied to the spring side of the valve and between lands #3 and #4. 2-3 Shift Valve - After Shift As vehicle speed increases, governor pressure increases proportionately, until it becomes great enough to overcome the combined throttle and spring pressure on the right side of the valve. Since the throttle pressure end of the 2-3 shift valve is larger in diameter than the 1-2 shift valve, the 2-3 shift will always happen at a greater speed than the 1-2 shift. When this happens, the governor plug is forced against the shift valve moving it to the right. The shift valve causes land #4 to close the passage supplying throttle pressure to the 2-3 shift valve. Without throttle pressure present in the circuit now, the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8580 governor plug will push the valve over far enough to bottom the valve in its bore. This allows land #2 to direct line pressure to the front clutch. After the shift, line pressure is directed to the release side of the kickdown servo. This releases the front band and applies the front clutch, shifting into third gear or direct drive. The rear clutch remains applied, as it has been in the other gears. During a manual "1" or manual "2" gear selection, line pressure is sent between the two lands of the 2-3 governor plug. This line pressure at the governor plug locks the shift valve into the second gear position, preventing an upshift into direct drive. The theory for the blocking of the valve is the same as that of the 1-2 shift valve. If the manual "2" or manual "1" gear position is selected from the drive position, the PCM will control the timing of the downshift by targeting for a high governor pressure. When a safe vehicle speed is reached, the PCM will switch to its normal control governor curve and the downshift will occur. 3-4 SHIFT VALVE 3-4 Shift Valve Before Shift The PCM energizes the overdrive solenoid during the 3-4 upshift. This causes the solenoid check ball to close the vent port allowing line pressure from the 2-3 shift valve to act directly on the 3-4 upshift valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8581 3-4 Shift Valve After Shift Line pressure on the 3-4 shift valve overcomes valve spring pressure moving the valve to the upshift position. This action exposes the feed passages to the 3-4 timing valve, 3-4 quick fill valve, 3-4 accumulator, and ultimately to the overdrive piston. 3-4 TIMING VALVE 3-4 Shift Valve After Shift The 3-4 timing valve is moved by line pressure coming through the 3-4 shift valve or the converter clutch valve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8582 3-4 Shift Valve Before Shift After the shift, the timing valve holds the 2-3 shift valve in an upshift position. The purpose is to prevent the 2-3 valve from downshifting while either the overdrive clutch or converter clutch is applied. 3-4 QUICK FILL VALVE 3-4 Shift Valve Before Shift The 3-4 quick fill valve provides faster engagement of the overdrive clutch during 3-4 upshifts. The valve temporarily bypasses the clutch piston feed orifice at the start of a 3-4 upshift. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8583 3-4 Shift Valve After Shift This exposes a larger passage into the piston retainer resulting in a much faster clutch fill and apply sequence. The quick fill valve does not bypass the regular clutch feed orifice throughout the 3-4 upshift. Instead, once a predetermined pressure develops within the clutch, the valve closes the bypass. Clutch fill is then completed through the regular feed orifice. THROTTLE VALVE Throttle Valve In all gear positions, the throttle valve is being supplied with line pressure. The throttle valve meters and reduces the line pressure that now becomes throttle pressure. The throttle valve is moved by a spring and the kickdown valve, which is mechanically connected to the throttle. The larger the throttle opening, the higher the throttle pressure (to a maximum of line pressure). The smaller the throttle opening, the lower the throttle pressure (to a minimum of zero at idle). As engine speed increases, the increase in pump speed increases pump output. The increase in pressure and volume must be regulated to maintain the balance within the transmission. To do this, throttle pressure is routed to the reaction area on the right side of the throttle pressure plug (in the regulator valve). The higher engine speed and line pressure would open the vent too far and reduce line pressure too much. Throttle pressure, which increases with engine speed (throttle opening), is used to oppose the movement of the pressure valve to help control the metering passage at the vent. The throttle pressure is combined with spring pressure to reduce the force of the throttle pressure plug on the pressure valve. The larger spring at the right closes the regulator valve passage and maintains or increases line pressure. The increased line pressure works against the reaction area of the line pressure plug and the Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8584 reaction area left of land #3 simultaneously moves the regulator valve train to the right and controls the metering passage. The kickdown valve, along with the throttle valve, serve to delay upshifts until the correct vehicle speed has been reached. It also controls downshifts upon driver demand, or increased engine load. If these valves were not in place, the shift points would be at the same speed for all throttle positions. The kickdown valve is actuated by a cam connected to the throttle. This is accomplished through either a linkage or a cable. The cam forces the kickdown valve toward the throttle valve compressing the spring between them and moving the throttle valve. As the throttle valve land starts to uncover its port, line pressure is "metered" out into the circuits and viewed as throttle pressure. This increased throttle pressure is metered out into the circuits it is applied to: the 1-2 and 2-3 shift valves. When the throttle pressure is high enough, a 3-2 downshift will occur. If the vehicle speed is low enough, a 2-1 downshift will occur. SWITCH VALVE Switch Valve - Torque Converter Unlocked When the transmission is in Drive Second before the TCC application occurs, the pressure regulator valve is supplying torque converter pressure to the switch valve. The switch valve directs this pressure through the transmission input shaft, into the converter, through the converter, back out between the input shaft and the reaction shaft, and back up to the switch valve. From the switch valve, the fluid pressure is directed to the transmission cooler, and lubrication pressure returns from the cooler to lubricate different portions of the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8585 Switch Valve - Torque Converter Locked MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the side of the valve body. The valve is connected mechanically by either a cable or linkage to the gearshift mechanism. The valve is held in each of its positions by a spring-loaded roller or ball that engages the "roostercomb" of the manual valve lever. Manual Valve Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8586 Once the TCC control valve has moved to the right, line pressure is directed to the tip of the switch valve, forcing the valve to the right. The switch valve now vents oil from the front of the piston in the torque converter, and supplies line pressure to the (rear) apply side of the torque converter piston. This pressure differential causes the piston to apply against the friction material, cutting off any further flow of line pressure oil. After the switch valve is shuttled right allowing line pressure to engage the TCC, torque converter pressure is directed past the switch valve into the transmission cooler and lubrication circuits. CONVERTER CLUTCH LOCK-UP VALVE The torque converter clutch (TCC) lock-up valve controls the back (ON) side of the torque converter clutch. When the PCM energizes the TCC solenoid to engage the converter clutch piston, pressure is applied to the TCC lock-up valve which moves to the right and applies pressure to the torque converter clutch. CONVERTER CLUTCH LOCK-UP TIMING VALVE The torque converter clutch (TCC) lock-up timing valve is there to block any 4-3 downshift until the TCC is completely unlocked and the clutch is disengaged. SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves. When the manual valve is positioned in the Drive range, throttle pressure acts on the throttle plug of the shuttle valve to move it against a spring, increasing the spring force on the shuttle valve. During a part or full throttle 1-2 upshift, the throttle plug is bottomed by throttle pressure, holding the shuttle valve to the right against governor pressure, and opening a by-pass circuit. The shuttle valve controls the quality of the kickdown shift by restricting the rate of fluid discharge from the front clutch and servo release circuits. During a 3-2 kickdown, fluid discharges through the shuttle by-pass circuit. When the shuttle valve closes the by-pass circuit, fluid discharge is restricted and controlled for the application of the front band. During a 2-3 "lift foot" upshift, the shuttle valve by-passes the restriction to allow full fluid flow through the by-pass groove for a faster release of the band. BOOST VALVE Boost Valve Before Lock-up The boost valve provides increased fluid apply pressure to the overdrive clutch during 3-4 upshifts, and when accelerating in fourth gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8587 Boost Valve After Lock-up The boost valve also serves to increase line pressure during torque converter lock-up. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8588 Valve Body: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch and frictional clutches. The valve body contains the following components: - Solenoid switch valve - Manual valve - Low/reverse shuttle valve - 5 Accumulators - 7 check balls Operation OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. SOLENOID SWITCH VALVE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8589 The Solenoid Switch Valve (SSV) controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. The Solenoid Switch Valve controls line pressure from the LR-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In all other gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the top of the valve body. The valve is connected mechanically to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (2) that engages the roostercomb of the TRS selector plate (1). LOW/REVERSE SWITCH VALVE The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8590 Valve Body: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The valve body consists of a two piece aluminum valve body. Extensive electronic control effected by a microcomputer (the automatic transmission electronic control unit) over the hydraulic circuitry enables precise control over gearshifts. The valve body contains valves and pressure sensors that control fluid delivery to the torque converter clutch, forward clutches, and brake clutches. UPPER VALVE BODY UPPER VALVE BODY The upper valve body contains the following components: - 1 = Combined Drain - 2 = Gain change solenoid valve - 3 = Manual valve - 4 = Modulator valve - 5 = Shift solenoid valve No. 3 - 6 = Shift solenoid valve No. 2 - 7 = Shift valve No. 1 LOWER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8591 LOWER VALVE BODY The lower valve body contains the following components: - 1 = Control valve No. 3 - 2 = Shift solenoid valve No. 4 - 3 = Lockup control valve - 4 = Control valve No. 1 - 5 = Control valve No. 2 SWITCHES AND SOLENOIDS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8592 VALVE BODY OIL SWITCH HARNESS There are eight pressure switches and one ATF temperature switch used to inform the Transmission Control Module (TCM) when there is pressure in various hydraulic circuits. Six of them are located on the bottom of the valve body. The remainder are located on the top of the valve body. SWITCHES AND SOLENOIDS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8593 VALVE BODY SOLENOID HARNESS Eight solenoids are used to control various shift functions in the transmission. Four are located on the top of the valve body (3, 4) and the remainder are located on the bottom of the valve body. Operation OPERATION LOWER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8594 LOWER VALVE BODY UPPER VALVE BODY Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8595 UPPER VALVE BODY SWITCHES AND SOLENOIDS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8596 VALVE BODY OIL SWITCH HARNESS SWITCHES AND SOLENOIDS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 8597 VALVE BODY SOLENOID HARNESS Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures Valve Body: Procedures Cleaning CLEANING Clean the valve housings, valves, plugs, springs, transfer plate and separator plate with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Inspection INSPECTION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8600 NOTE: Only the INNER accumulator seal ring actually seals the pressure in the bore. The outer seal ring only serves to guide the piston in the bore. Gouges which do not extend past the inner seal ring (and have no raised edges, which could damage the guide ring) are acceptable. The machined accumulator bores often have a tiger-striped appearance. This is NORMAL and does NOT require replacement, as long as the bores are smooth in the inner seal ring area. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not normally change dimensionally with use. If the valve body functioned correctly when new, it should continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Inspect all the accumulator bores in the valve body as well as the accumulator piston seal rings, and replace if cut or damaged. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the accumulator springs. The springs must be free of distortion, warpage or broken coils. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8601 Inspect all the fluid seals on the valve body. Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Cleaning CLEANING Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has sustained physical damage (dented, deformed, broken, etc.). CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing. Inspection INSPECTION Inspect the throttle and manual valve levers and shafts. Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way. Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances. This practice could damage the special coating causing the valves/plugs to stick and bind. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8602 Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are: - dual solenoid and harness assembly - solenoid gasket - solenoid case connector O-rings and shoulder bolt - switch valve and spring - pressure adjusting screw and bracket assembly - throttle lever - manual lever and shaft seal - throttle lever shaft seal, washer, and E-clip - fluid filter and screws - detent ball and spring - valve body screws - governor pressure solenoid - governor pressure sensor and retaining clip - park lock rod and E-clip Cleaning CLEANING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8603 UPPER VALVE BODY LOWER VALVE BODY Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8604 SOLENOID FILTER SCREEN Clean the solenoid filter screen (1), (if equipped). Inspection INSPECTION Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8605 SOLENOID FILTER SCREEN Inspect all solenoid filter screens (1). Inspect all the fluid seals in the transmission case. Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8606 Valve Body: Removal and Replacement Removal REMOVAL NOTE: The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disconnect wires at the solenoid and pressure switch assembly 23 pin electrical connector. 4. Position drain pan under transmission oil pan. 5. Remove transmission oil pan. 6. Remove the primary oil filter (1) from valve body. 7. Remove bolts (1) attaching valve body to transmission case. 8. Lower the valve body and work the electrical connector out of transmission case. 9. Separate the valve body from the transmission. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8607 1. Place TRS selector plate in the PARK position. 2. Place the transmission in the PARK position. 3. Lubricate seal on the solenoid and pressure switch assembly connector with petroleum jelly. 4. Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever. 5. Seat valve body in case and install one or two bolts to hold valve body in place. 6. Tighten valve body bolts alternately and evenly to 12 Nm (105 in. lbs.) torque. 7. Operate the external manual shift lever and ensure that the TRS selector plate moves correctly into all gear range positions. CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 8. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 9. Place replacement filter (1) in position on valve body and into the oil pump. 10. Install screw to hold filter to valve body. Tighten screw to 4.5 Nm (40 in. lbs.) torque. 11. Connect the solenoid and pressure switch 23 pin electrical assembly connector. 12. Install oil pan using silicone gasket sealer. Tighten pan bolts to 12 Nm (105 in. lbs.) torque. 13. Lower vehicle and fill transmission with Mopar(R) ATF +4. 14. Check and adjust gearshift cable, if necessary. Removal REMOVAL NOTE: The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. CAUTION: If replacing the valve body an oil pump must be replaced as these are a matched set. Failure to follow these instructions may result in transmission failure and permanent damage. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8608 DRAIN PLUG 1. Shift transmission into PARK. 2. Raise vehicle. 3. Position drain pan under transmission oil pan. 4. Remove transmission oil pan drain plug (1) and drain oil. 5. Remove transmission oil pan. 6. Remove the transmission filter. 7. Disconnect electrical harness connectors from valve body and position harness aside. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8609 8. Remove all the bolts, clamp, wave washer, manual detent spring and cover (2-13,15), attaching the valve body (1) to the transmission case (14). 9. Remove the valve body on a slight angle to clear the manual valve shaft (3) from the roostercomb (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8610 OVER HEAD VIEW 10. Remove the three accumulator springs and the three accumulators (1), (2),(3). CAUTION: Do not remove the valve body electrical harnesses from the transmission case unless replacement is required. Failure to follow these instructions may create an external transmission fluid leak path. 11. Remove the bolts (1) securing the valve body electrical harness connectors to the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8611 12. Remove both valve body electrical harnesses (1) from the transmission case. Installation INSTALLATION CAUTION: If the valve body is being replaced the oil pump must also be replaced. Failure to follow these instructions will damage the transmission. NOTE: If the valve body is being replaced, a quick learn must be performed using the scan tool. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn NOTE: Apply petroleum grease to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. 1. Lubricate the seals on the electrical connectors with MOPAR(R) AS68RC ATF and install the valve body electrical harnesses (1) into the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8612 2. Install the valve body electrical harness connector bolts. Tighten the bolts to 8 Nm (71 in.lbs.). OVER HEAD VIEW 3. Install the three accumulator springs first and then the three accumulator valves (1), (2),(3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8613 VALVE BODY INSTALLATION NOTE: Install valve body on a slight angle and verify that the shaft on the manual shift valve and the roller detent spring (11) has properly engaged the manual valve lever (13). NOTE: Bolts with conical washers are not reusable. 4. Install the valve body onto the transmission case. 5. Install and then tighten the bolts in the following order: a. Install bolts (2*) and (3*) and tighten by hand in order to hold valve body onto transmission case. b. Install detent spring, (10), (11) and bolts (5), (8) with wave washer (9), and tighten by hand. c. Install clamp (12) along with bolt (15) on the prescribed position and tighten by hand. d. Install bolts (15), (4), (6) and (7) on each correct position and tighten by hand. e. Tighten bolts (2*) and (3*) to 10 Nm ( 88 in.lbs.). f. Tighten bolts (4), (5), (6),(7), (15) to 10 Nm ( 88 in.lbs.) and (8) to 5.5 Nm (49 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8614 VALVE BODY SOLENOID HARNESS 6. Install the white wire onto the oil pressure switch number seven (5). 7. Install the black wire onto the oil pressure switch number eight (6). 8. Connect the blue/white wire into linear solenoid number three (3). 9. Connect the yellow/black wire into linear solenoid number one (4). 10. Connect the brown/red wire to the oil temperature sensor (7) jumper harness. 11. Connect the orange/green to the upper valve body jumper harness (10). 12. Secure the valve body solenoid harness at clamps (8) and (9). NOTE: There should be no harness wires between the two arrows. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8615 VALVE BODY OIL SWITCH HARNESS 13. Install the yellow wire onto oil pressure switch number six (9). 14. Install the black wire onto oil pressure switch number three (10). 15. Install the red wire onto oil pressure switch number two (11). 16. Install the brown wire onto oil pressure switch number one (12). 17. Connect the blue/white wire into linear solenoid number four (3). 18. Connect the brown/red wire into linear solenoid number two (6). 19. Connect the yellow wire into the on/off solenoid number three (4). 20. Connect the black wire into the on/off solenoid number two (5). 21. Connect the green wire into the on/off solenoid number one (7). 22. Connect the orange wire into the on/off solenoid number four (8). 23. Secure the oil pressure switch harness that is protected with clamps (13), (14) and (15). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8616 TRANSMISSION OIL FILTER 24. Lubricate transmission oil filter o-ring with MOPAR(R) AS68RC ATF. 25. Install the transmission oil filter (2) into the valve body (1). 26. Install the bolts (3) and tighten to 10 Nm (88 in.lbs.). OIL PAN MAGNETS NOTE: Before installing the transmission oil pan be certain to inspect and clean the pick-up magnets (1) as well as the magnetic drain plug bolt (2). 27. Using a new gasket install the oil pan onto the transmission case. 28. Tighten oil pan bolts to 7 Nm (62 in.lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8617 DRAIN PLUG 29. Install oil pan drain plug bolt (1). Tighten bolt to 27 Nm (20 ft. lbs.) 30. Lower vehicle and fill transmission with MOPAR(R) AS68RC ATF. 31. Check and adjust gearshift cable, if necessary. Removal REMOVAL The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. The only replaceable valve body components are: - Manual lever. - Manual lever washer, seal, E-clip, and shaft seal. - Manual lever detent ball. - Throttle lever. - Fluid filter. - Pressure adjusting screw bracket. - Governor pressure solenoid. - Governor pressure sensor (includes transmission temperature thermistor). - Converter clutch/overdrive solenoid assembly and harness. - Governor housing gasket. - Solenoid case connector O-rings. 1. Shift transmission into NEUTRAL. 2. Raise vehicle. 3. Remove gearshift and throttle levers from shaft of valve body manual lever. 4. Disconnect wires at solenoid case connector (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8618 5. Remove the transmission range sensor (2) See: Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service and Repair/48RE (A-618) 4 Speed/Removal . 6. Position drain pan under transmission oil pan. 7. Remove transmission oil pan and gasket. 8. Remove fluid filter from valve body. 9. Remove bolts attaching valve body to transmission case. 10. Lower valve body enough to remove accumulator piston and springs. 11. Work manual lever shaft and electrical connector out of transmission case. 12. Lower valve body (1), rotate valve body away from case, pull park rod (3) out of sprag, and remove valve body. Installation INSTALLATION 1. Check condition of O-ring seals (1) on valve body harness connector (2). Replace seals on connector body if cut or worn. 2. Check condition of manual lever shaft seal (2) in transmission case. Replace seal if lip is cut or worn. Install new seal with 15/16 deep well socket Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8619 (1). 3. Check condition of seals on accumulator piston. Install new piston seals, if necessary. 4. Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag. 5. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case. 6. Lubricate seal rings on valve body harness connector with petroleum jelly. 7. Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod to check engagement. CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity. 8. Install accumulator spring and piston into case. Then swing valve body over piston and outer spring to hold it in place. 9. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. 10. Then seat valve body in case and install one or two bolts to hold valve body in place. 11. Tighten valve body bolts alternately and evenly to 11 Nm (100 in. lbs.) torque. 12. Install new fluid filter on valve body. Tighten filter screws to 4 Nm (35 in. lbs.) torque. 13. Install throttle and gearshift levers on valve body manual lever shaft. 14. Check and adjust front and rear bands if necessary. 15. Install the transmission range sensor See: Sensors and Switches A/T/Transmission Position Switch/Sensor/Service and Repair/48RE (A-618) 4 Speed/Installation 16. Connect solenoid case connector wires. 17. Install oil pan and new gasket. Tighten pan bolts to 13.6 Nm (125 in. lbs.) torque. 18. Lower vehicle and fill transmission with Mopar(R) ATF +4, Automatic Transmission fluid. 19. Check and adjust gearshift and throttle valve cables, if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8620 Valve Body: Overhaul Disassembly DISASSEMBLY 1. Remove the bolts (1) holding the solenoid and pressure switch assembly to the valve body. Do not remove the screws on the top of the solenoid and pressure switch assembly. 2. Separate the solenoid and pressure switch assembly from the valve body. 3. Remove the screw holding the detent spring (2) onto the valve body. 4. Remove the detent spring (2) from the valve body. 5. Remove the TRS selector plate (1) from the valve body and the manual valve. 6. Remove the clutch passage seals (3) from the valve body, if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8621 7. Remove the screws holding the accumulator cover onto the valve body. 8. Remove the accumulator springs and pistons (1, 6-9) from the valve body. Note which accumulator piston and spring belong in each location. 9. Place the valve body on the bench with the transfer plate upward. NOTE: The valve body contains seven check balls. The transfer plate must be placed upward to prevent losing the check balls when the transfer plate is removed from the valve body. 10. Remove the screws holding the valve body to the valve body transfer plate. 11. Remove the transfer plate from the valve body. Note the location of all check balls. 12. Remove the check balls from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8622 13. Remove the retainer securing the solenoid switch valve (5) from the valve body. Remove the solenoid switch valve and plugs (5), the manual valve (4) and low reverse shuttle valve and plug (2). Tag each valve and plug combination with location information to aid in assembly. Assembly ASSEMBLY 1. Lubricate valves, plugs and the housing valve bores with clean transmission fluid. 2. Install solenoid switch valve and plugs and plugs (5) and the retainer into the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8623 3. Install the valve body check balls into their proper locations. 4. Position the separator and transfer plate onto the valve body. 5. Install the screws to hold the transfer plate to the valve body. Tighten the screws to 6 Nm (50 in. lbs.). 6. Install the accumulator piston seal rings onto each accumulator piston. 7. Install the accumulator pistons (1, 6-9) and springs into the valve body in the location from which they were removed. Note that all accumulators except the overdrive have two springs. The overdrive accumulator piston (6) has only one spring. 8. Install the Low / Reverse shuttle valve, plug, and retainer (2) into the valve body housing. 9. Position the accumulator cover onto the valve body. 10. Install the screws to hold the accumulator cover onto the valve body. Tighten the screws to 7 Nm (60 in. lbs.). 11. Install the manual valve (4). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8624 12. Install the TRS selector plate (1) onto the valve body and the manual valve. 13. Position the detent spring (2) onto the valve body. 14. Install the screw to hold the detent spring (2) onto the valve body. Tighten the screw to 4.5 Nm (40 in. lbs.). 15. Install new clutch passage seals (3) onto the valve body, if necessary. 16. Install the solenoid and pressure switch assembly onto the valve body. 17. Install the bolts (1) to hold the solenoid and pressure switch assembly onto the valve body. Tighten the bolts to 6 Nm (50 in. lbs.). Tighten the bolts adjacent to the arrows cast into the bottom of the transfer plate first. Disassembly DISASSEMBLY CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8625 1. Disconnect wires from governor pressure sensor and solenoid. 2. Remove screws attaching governor body and retainer plate to transfer plate. 3. Remove retainer plate, governor body and gasket from transfer plate. 4. Remove governor pressure sensor from governor body. 5. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove and discard solenoid O-rings if worn, cut, or torn. 6. Remove small shoulder bolt that secures solenoid harness case connector (1) to 3-4 accumulator housing (2). Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. 7. Unhook overdrive/converter solenoid harness (1) from 3-4 accumulator cover plate (2). 8. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly (1) to valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8626 9. Remove solenoid and harness (6) assembly from valve body. 10. Remove boost valve cover (1). 11. Remove boost valve retainer (1), valve spring (6), and boost valve (5). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8627 12. Secure detent ball and spring with Retainer Tool 6583 (1). 13. Remove park rod E-clip (2) and separate rod (3) from manual lever (1). 14. Remove E-clip and washer (2) that retains throttle lever shaft (1) in manual shaft (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8628 15. Remove manual lever (2) and throttle lever (3). Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. 16. Position pencil magnet (4) next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball (3) and spring (2). 17. Remove screws (2) attaching pressure adjusting screw bracket (3) to valve body and transfer plate. Hold bracket (5) firmly against spring tension while removing last screw (5). 18. Remove adjusting screw bracket (4), line pressure adjusting screw (2), pressure regulator valve spring (5), and switch valve spring (1). Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8629 Upper Housing Control Valve Locations 19. Turn upper housing (1) over and remove switch valve (3), regulator valve (2) and spring (4), and manual valve (8). 20. Remove kickdown detent (6), kickdown valve (5), and throttle valve and spring (7). 21. Loosen left-side 3-4 accumulator housing (3) attaching screw (1) about 2-3 threads. Then remove center and right-side housing attaching screws (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8630 22. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring. 23. Remove left-side screw and remove 3-4 accumulator housing (3) from valve body. 24. Bend back tabs on boost valve tube brace (2). 25. Remove boost valve connecting tube (1). Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8631 out of lower housing. CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only. 26. Turn valve body over so lower housing (1) is facing upward. In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed. 27. Remove screws attaching valve body lower housing (1) to upper housing and transfer plate (3). Note position of boost valve tube brace for assembly reference. 28. Remove lower housing and overdrive separator plate (2) from transfer plate (3). 29. Remove the Number 10 check ball (1) from the transfer plate. The check ball is approximately 4.8 mm (3/16 in.) in diameter. 30. Remove transfer plate (2) from upper housing (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8632 31. Turn transfer plate (1) over so upper housing separator plate (2) is facing upward. 32. Remove upper housing separator plate (2) from transfer plate (1). Note position of filter screen (3) in separator plate for assembly reference. 33. Remove rear clutch steel check ball (1) and rear servo plastic check ball (2) from transfer plate (3). Note check ball location for assembly reference. VALVE BODY UPPER HOUSING 1. Note location of check balls (1, 2) in valve body upper housing. Then remove the one large diameter (2) and the six smaller diameter (1) check balls. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8633 2. Remove E-clip (1) that secures shuttle valve secondary spring (2) on valve stem (3). Shuttle and Boost Valve Location 3. Remove governor plug and shuttle valve covers (8). 4. Remove throttle plug (12), primary spring (10), shuttle valve (9), secondary spring (7), and spring guides (5). 5. Remove boost valve retainer, spring and valve if not previously removed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8634 Upper Housing Shift Valve and Pressure Plug Locations 6. Remove throttle plug and 1-2 and 2-3 governor plugs. 7. Turn upper housing (1) around and remove limit valve (6) and shift valve covers. 8. Remove limit valve housing (5). Then remove retainer, spring, limit valve (7), and 2-3 throttle plug (4) from limit valve housing (5). 9. Remove 1-2 shift control valve and spring (9). 10. Remove 1-2 shift valve and spring (2). 11. Remove 2-3 shift valve and spring (3) from valve body. 12. Remove pressure plug cover (10). 13. Remove throttle pressure plug and spring (12). VALVE BODY LOWER HOUSING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8635 Lower Housing Shift Valves and Springs 3-4 ACCUMULATOR HOUSING 1. Remove end plate from housing. 2. Remove piston spring. 3. Remove piston. Remove and discard piston seals. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8636 4. Remove timing valve cover. 5. Remove 3-4 timing valve and spring. 6. Remove 3-4 quick fill valve, spring and plug. 7. Remove 3-4 shift valve and spring. 8. Remove converter clutch valve, spring and plug. 9. Remove converter clutch timing valve, retainer and valve spring. Assembly ASSEMBLY CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended tightening specifications only. LOWER HOUSING Lower Housing Shift Valves and Springs Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8637 1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2. Install 3-4 timing valve spring and valve (13) in lower housing. 3. Install 3-4 quick fill valve (18) in lower housing. 4. Install 3-4 quick fill valve spring (18) and plug (12) in housing. 5. Install timing valve end plate (11). Tighten end plate screws to 4 Nm (35 in. lbs.) torque. 3-4 ACCUMULATOR 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings (3) on accumulator piston. 3. Install piston (1) and spring (4) in housing. 4. Install end plate on housing (5). TRANSFER PLATE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8638 1. Install rear clutch steel check ball (1) and rear servo plastic check ball (2) into the transfer plate (3). 2. Install filter screen (2) in upper housing separator plate (1). 3. Align and position upper housing separator plate (3) on transfer plate (2). 4. Install brace plate (1). Tighten brace attaching screws to 4 Nm (35 in. lbs.) torque. 5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 in. lbs.) torque. UPPER AND LOWER HOUSING 1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing (1, 2). Seven check balls are used. The single large check ball (2) is approximately 8.7 mm (11/32 in.) diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 in.) in diameter. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8639 2. Position assembled transfer plate and upper housing separator plate (2) on upper housing. Be sure filter screen (1) is seated in proper housing recess. 3. Install the Number 10 check ball (1) into the transfer plate. The check ball is approximately 4.8 mm (3/16 in.) in diameter. 4. Position lower housing separator plate (3) on transfer plate (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8640 5. Install lower housing (2) on assembled transfer plate (4) and upper housing (3). 6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 in. lbs.) torque. Start at center and work out to sides when tightening screws (1). UPPER HOUSING VALVE AND PLUG Refer to the following graphic, to perform the following steps. 1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Install the boost valve plug (4), boost valve (3), spring (1), and retainer (2) into the housing. 3. Install the boost valve cover (14). Tighten cover plate screws to 4 Nm (35 in. lbs.) torque. 4. Install shuttle valve as follows: a. Insert plastic guides (5) in shuttle valve secondary spring (7) and install spring on end of shuttle valve (9). b. Install shuttle valve (9) into housing. c. Hold shuttle valve in place. d. Compress secondary spring (7) and install E-clip (6) in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before proceeding. 5. Install shuttle valve cover plate (8). Tighten cover plate screws to 4 Nm (35 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8641 6. Install 1-2 (9) and 2-3 (12) valve governor plugs in valve body. 7. Install shuttle valve primary spring (13) and throttle plug (11). 8. Align and install governor plug cover (11). Tighten cover screws to 4 Nm (35 in. lbs.) torque. 9. Install the switch valve (3). 10. Install the throttle valve and spring (7), kickdown (5), and kickdown detent (6). 11. Install the manual valve (8). 12. Assemble regulator valve (2) and spring (4). Insert assembly in upper housing. Upper Housing Shift Valve and Pressure Plug Locations 13. Install 1-2 (2) and 2-3 (3) shift valves and springs. 14. Install 1-2 shift control valve and spring (9). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8642 15. Install retainer (8), limit valve and spring (7), and 2-3 throttle plug (4) into the limit valve housing (5). 16. Install the throttle pressure spring and plug (12) and plug sleeve (11). 17. Install pressure plug cover (10) and cover plate (6). Tighten screws to 4 Nm (35 in. lbs.). 18. Install limit valve housing (5) and cover plate (6). Tighten screws to 4 Nm (35 in. lbs.). BOOST VALVE TUBE AND BRACE 1. Position valve body assembly so lower housing (2) is facing upward. 2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. 3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port. 4. Insert and seat each end of tube in housings. 5. Slide tube brace (2) under tube and into alignment with valve body screw holes. 6. Install and finger tighten three screws that secure tube brace to valve body housings. 7. Bend tube brace tabs up and against tube to hold it in position. 8. Tighten all valve body housing screws to 4 Nm (35 in. lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward. 3-4 ACCUMULATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8643 1. Position converter clutch valve (4) and 3-4 shift valve (3) springs in housing. 2. Loosely attach accumulator housing (2) with right-side screw (1). Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. 3. Install 3-4 shift valve and spring (3). 4. Position plug (2) on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. 5. Swing accumulator housing upward over valve springs and plug. 6. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 in. lbs.). VALVE BODY FINAL 1. Insert manual lever detent spring in upper housing. 2. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583 (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8644 3. Install throttle lever (1) in upper housing. Then install manual lever (2) over throttle lever and start manual lever into housing. 4. Align manual lever with detent ball and manual valve (3). Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated. 5. Then install manual lever seal, washer and E-clip. 6. Verify that throttle lever is aligned with end of kickdown valve (4) stem and that manual lever arm is engaged in manual valve. 7. Lubricate solenoid case connector (1) O-rings and shaft of manual lever with light coat of petroleum jelly. 8. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing (2). Seat tang in dimple before tightening connector screw. 9. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 in. lbs.) torque. 10. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover. 11. Position line pressure adjusting screw in adjusting screw bracket. 12. Install switch valve spring on tang at end of adjusting screw bracket. 13. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 in. lbs.) torque. 14. Perform Line Pressure and Throttle Pressure adjustments. See: Adjustments/Valve Body GOVERNOR BODY, SENSOR AND SOLENOID Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8645 1. Turn valve body assembly over so accumulator side of transfer plate is facing down. 2. Install new O-rings on governor pressure solenoid and sensor. 3. Lubricate solenoid and sensor O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. 5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body. 6. Position governor body gasket on transfer plate. 7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 in. lbs.) torque. 9. Connect harness wires to governor pressure solenoid and governor pressure sensor. 10. Install fluid filter and pan. 11. Lower vehicle. 12. Fill transmission with recommended fluid and road test vehicle to verify repair. Disassembly DISASSEMBLY 1. Remove all the bolts holding the on/off solenoids in place. 2. Remove all the on/off solenoids. 3. Remove the bolts holding the linear solenoid bracket in place and remove solenoid bracket. 4. Remove all the linear solenoids. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8646 VALVE BODY PRESSURE SENSOR 5. Remove all the pressure sensors from the lower valve body. SEPARATOR PLATE 6. Remove all the bolts connecting the lower valve body to the upper valve body. 7. Disassemble the lower valve body and separator plate from the upper valve body. 8. Remove the separator plate (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8647 UPPER VALVE BODY PRESSURE SENSOR 9. Remove the upper valve body pressure sensors (1). CHECK BALLS 10. Remove all the check balls (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8648 CHECK VALVES 11. Remove all check valves. VALVES 12. Remove all valves (1). Assembly ASSEMBLY NOTE: Apply petroleum grease to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8649 VALVES 1. Install all the valves (1). CHECK VALVES 2. Install all the check valves (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8650 CHECK BALLS 3. Install all the check balls (1). VALVE BODY PRESSURE SENSOR 4. Install the oil pressure switches onto the upper valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8651 UPPER VALVE BODY PRESSURE SENSOR 5. Tighten the oil pressure switches (1) to 4.4 Nm (38 in lbs.). SEPARATOR PLATE 6. Install the separator plate onto the lower valve body. 7. Install the separator plate (1) bolts and tighten bolts in a crisscross manner to 10 Nm (88 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8652 SWITCHES AND SOLENOIDS NOTE: Tighten all bolts in order specified. 8. Install the upper valve body onto the lower valve body. 9. Install the valve body bolts and tighten in a crisscross manner to 5.5 Nm ( 49 in.lbs.). 10. Install oil pressure switch (7) and (8) in the correct positions. 11. Tighten oil pressure switch (7) to 4.4 Nm (39 in.lbs.). 12. Tighten oil pressure switch (8) to 8.5 Nm (75 in.lbs.). 13. Install temperature sensor (11). 14. Install temperature sensor jumper harness (12) onto temperature sensor (11) and secure to valve body. 15. Lubricate o-rings (if equipped) with MOPAR(R) AS68RC ATF and install on/off solenoids (4). 16. Install on/off solenoid bolts (2) and (3). 17. Tighten bolts (2) to 5.5 Nm (49 in.lbs.) and (3) to 10 Nm ( 88 in.lbs.). 18. Lubricate o-rings with MOPAR(R) AS68RC ATF and install linear solenoids (9). 19. Install linear solenoid bracket (10). 20. Install linear solenoid bracket bolts (5) and (6). 21. Tighten linear solenoid bracket bolt (5) to 10 Nm (88 in.lbs.). 22. Tighten linear solenoid bracket bolt (6) to 10 Nm (88 in.lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Procedures > Page 8653 UPPER VALVE BODY HARNESS NOTE: When installing the jumper harness, fix the harness portion that is protected with the clamp. 23. Install the jumper harness (5) into the clamp (4). NOTE: Install the oil pressure switch connector (2) so that the orientation of the connector will be in a range of 0-90 degrees downward. 24. Connect the green wire of the jumper harness to the oil pressure switch (2). NOTE: Install the oil pressure switch connector (3) so that the orientation of the connector will be in a range of 0-45 degrees downward. 25. Connect the orange wire of the jumper harness to the oil pressure switch (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Adjustments Clutch Disc: Adjustments PRESSURE PLATE DIAPHRAGM SPRINGS NOTE:Perform the following procedure, when replacing only the clutch disc on Diesel vehicles with Dual Mass Flywheel and self- adjusting pressure plate. The pressure plate must be reset before installing a new disc. 1. Support pressure plate flange with press blocks (3) on a press. 2. Center press ram (2) on the pressure plate diaphragm spring fingers (1). 3. Compress the diaphragm spring fingers (1), until tension is released from the stepped adjusting ring. 4. Place two screwdrivers against two of the three stepped adjusting ring (1) tension spring stops, just ahead of the adjusting ring tension springs on the pressure plate (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Adjustments > Page 8658 5. Rotate stepped adjusting ring (1) on the pressure plate (2) counterclockwise until the coil springs are fully compressed. Then hold adjusting ring while releasing the press pressure. 6. Remove the screwdrivers. The pressure plate is know adjusted for a new clutch disc. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal Clutch Disc: Service and Repair Clutch Disc - Removal REMOVAL 1. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts. 2. Remove transmission and transfer case, if equipped. 3. If pressure plate (3) will be reused, mark (2) the position on flywheel (1) with paint or scriber. Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it. 4. Insert clutch alignment tool (3) through pressure plate (2) and into pilot bushing, to hold disc in place while removing bolts. 5. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove bolts completely and remove pressure plate, disc and alignment tool. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal > Page 8661 Clutch Disc: Service and Repair Clutch Disc - Installation INSTALLATION CAUTION: Before installing a clutch disc on the Diesel engine with Dual Mass Flywheel and self-adjusting pressure plate, the pressure plate must be reset. Refer to clutch disc adjustment for procedure. Failure to reset the pressure will result in damage to the clutch disc. 1. Check runout and free operation of new clutch disc. 2. Lubricate crankshaft pilot bearing with a NLGI - 2 rated grease. 3. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel. NOTE: Flywheel side is imprinted on the disc face. 4. Install alignment tool (3) in pilot bearing and position disc on the flywheel (1). 5. Position pressure plate over disc (2) and onto the flywheel. NOTE: Over the wear life of a clutch disc the pressure plate will loose some of it's clamp load. It is recommended when replacing a worn clutch, the pressure plate is replaced at the same time. 6. Align and hold pressure plate in position and install bolts finger tight. 7. Tighten bolts evenly and a few threads at a time in a diagonal pattern. CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. 8. Tighten pressure plate bolts to: - V6 & V8 Engines - 50 Nm (37 ft. lbs.) - Diesel Engines - 30 Nm (22 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal > Page 8662 9. Remove release lever (3) and release bearing from clutch housing (1). Apply Mopar(TM) high temperature bearing grease to bore (4) of release bearing, release lever (5) contact surfaces and release lever pivot stud (2). 10. Apply light coat of Mopar(TM) high temperature bearing grease to splines (3) of transmission input shaft (1) and to release bearing slide surface of the transmission front bearing retainer (2). CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc. 11. Wipe pilot bearing surface clean. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Clutch Disc - Removal > Page 8663 12. Install release lever and bearing in clutch housing. Verify spring clips (2) that retain lever on pivot ball (4) and release bearing (3) are installed properly. NOTE: If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped "I" in the lever which goes to the pivot ball side of the transmission. 13. Install transmission and transfer case if equipped. 14. Check fluid level in clutch master cylinder and depress clutch pedal several time. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8669 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Page 8670 Clutch Fluid: Specifications Chrysler does not provide a fluid type specification for the master/slave cylinder. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Component ID 472 Clutch Switch: Locations Component ID 472 Component ID: 472 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Component ID 472 > Page 8678 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Component ID 472 > Page 8679 Clutch Switch: Locations Component ID 482 Component ID: 482 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Component ID 472 > Page 8680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Component ID 472 Clutch Switch: Diagrams Component ID 472 Component ID: 472 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Component ID 472 > Page 8683 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Component ID 472 > Page 8684 Clutch Switch: Diagrams Component ID 482 Component ID: 482 Component : SWITCH-CLUTCH INTERLOCK Connector: Name : SWITCH-CLUTCH INTERLOCK Color : GREEN # of pins : 2 Qualifier : (M/T) Pin Circuit Description 1 T41 20YL/DB TRS T41 SIGNAL (P/N) 2 Z911 20BK GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams > Component ID 472 > Page 8685 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair > Removal Clutch Release Bearing: Service and Repair Removal REMOVAL 1. Remove transmission and transfer case, if equipped. 2. Remove spring clip (6). 3. Disconnect release bearing (4) from release lever (3) and remove bearing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair > Removal > Page 8690 Clutch Release Bearing: Service and Repair Installation INSTALLATION 1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked. 2. Inspect release lever (2) and pivot stud (1). Verify stud is secure and in good condition and lever is not distorted or worn. Replace fork spring clips if bent or damaged. 3. Lubricate input shaft splines, bearing retainer slide surface, pivot stud (1) and release lever pivot surface with Mopar(TM) high temperature bearing grease. 4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and release lever is installed properly. Rear side of release lever has one end with a raised area, which goes toward the slave cylinder side of the transmission. 5. Install transmission and transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair > Removal Clutch Release Fork: Service and Repair Removal REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Ensure cap on clutch cylinder reservoir is tight. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair > Removal > Page 8695 Clutch Release Fork: Service and Repair Installation INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Removal Pilot Bearing: Service and Repair Removal REMOVAL 1. Remove transmission assembly from the vehicle. 2. Remove pressure plate (2) and clutch disc. 3. Remove pilot bearing with an internal puller and slide hammer to remove. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Removal > Page 8700 Pilot Bearing: Service and Repair Installation INSTALLATION 1. Clean bearing bore with solvent and wipe dry with shop towel. 2. Install new bearing (1) with clutch alignment tool (2) and letter side of the bearing (3) facing the transmission. Bearing should be flush with edge of bearing bore. CAUTION: Do not allow bearing to become cocked and do not recess bearing. 3. Install clutch disc, pressure plate and transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure Plate Bolts - V6 AND V8....................................................................................................... ........................................................50 Nm (37 ft.lbs.) Pressure Plate Bolts - Diesel........................... ..............................................................................................................................................30 Nm (22 ft.lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8710 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8715 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8722 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8723 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 202 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Circuit Description 1 Z906 20BK GROUND 2 G304 20VT/DB FRONT AXLE LOCK CONTROL 3 A880 20DB/RD FUSED B(+) 4 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8728 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8729 Solenoid: Locations Solenoid-Locker-Front Component ID: 457 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T520 16YL/OR FRONT LOCKER SOURCE 2 T521 18YL/BK LOCKER SENSOR SUPPLY 3 T522 18YL/LB FRONT LOCKER SENSOR SENSE 4 T524 16YL/LG FRONT LOCKER RETURN Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8730 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8731 Solenoid: Locations Solenoid-Locker-Rear Component ID: 458 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T526 16YL/WT REAR LOCKER SOURCE 2 T523 18YL/BK LOCKER SENSOR SUPPLY 3 T527 18YL/TN REAR LOCKER SENSOR SENSE 4 T528 16YL/GY REAR LOCKER RETURN Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8732 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 202 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Circuit Description 1 Z906 20BK GROUND 2 G304 20VT/DB FRONT AXLE LOCK CONTROL 3 A880 20DB/RD FUSED B(+) 4 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8735 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8736 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 457 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T520 16YL/OR FRONT LOCKER SOURCE 2 T521 18YL/BK LOCKER SENSOR SUPPLY 3 T522 18YL/LB FRONT LOCKER SENSOR SENSE 4 T524 16YL/LG FRONT LOCKER RETURN Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8737 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8738 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 458 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T526 16YL/WT REAR LOCKER SOURCE 2 T523 18YL/BK LOCKER SENSOR SUPPLY 3 T527 18YL/TN REAR LOCKER SENSOR SENSE 4 T528 16YL/GY REAR LOCKER RETURN Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8739 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205FD Differential Cover: Service and Repair Front Axle - C205FD Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove vent hose. 3. Remove differential cover (1) bolts (2). 4. Remove cover and drain lubricant. Installation INSTALLATION 1. Apply a 4 mm (0.15 in.) bead of Mopar Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 2. Install cover (2) and identification tag. Tighten cover bolts in a criss-cross pattern to 23 Nm (17 ft. lbs.). 3. Fill differential to specifications. 4. Install fill plug. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205FD > Page 8744 Differential Cover: Service and Repair Front Axle - 275FBI Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove differential cover (1) fill plug (2). 3. Remove differential cover (1) bolts (2). 4. Remove cover and drain lubricant. Installation INSTALLATION 1. Clean sealing surface on cover and housing. 2. Apply a 4 mm (0.15 in.) bead of Mopar AXLE RTV (1) or equivalent to the housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205FD > Page 8745 CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 3. Install cover (1) and tighten bolts (2) in a criss-cross pattern to 46 Nm (34 ft. lbs.). 4. Fill differential to specifications. 5. Install cover (1) fill plug (2) and tighten to 60 Nm (44 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205FD > Page 8746 Differential Cover: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove drain plug. 3. Remove cover bolts. 4. Remove cover and drain lubricant. Installation INSTALLATION 1. Apply a 6.35mm (1/4 in.) bead of Mopar Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 2. Install cover and identification tag. Tighten cover bolts in a criss-cross pattern to 41 Nm (30 ft. lbs.). 3. Fill differential with lubricant to specifications. 4. Install fill plug. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Removal Actuator: Service and Repair Removal REMOVAL 1. Remove actuator wiring connector. 2. Remove actuator (1) bolts (2). 3. Remove actuator (1) from disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8752 Actuator: Service and Repair Installation INSTALLATION 1. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Removal > Page 8753 3. Install actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 4. Install disconnect actuator wiring connector. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front Solenoid: Locations Module-Axle Disconnect-Front Component ID: 202 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Circuit Description 1 Z906 20BK GROUND 2 G304 20VT/DB FRONT AXLE LOCK CONTROL 3 A880 20DB/RD FUSED B(+) 4 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8758 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8759 Solenoid: Locations Solenoid-Locker-Front Component ID: 457 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T520 16YL/OR FRONT LOCKER SOURCE 2 T521 18YL/BK LOCKER SENSOR SUPPLY 3 T522 18YL/LB FRONT LOCKER SENSOR SENSE 4 T524 16YL/LG FRONT LOCKER RETURN Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8760 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8761 Solenoid: Locations Solenoid-Locker-Rear Component ID: 458 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T526 16YL/WT REAR LOCKER SOURCE 2 T523 18YL/BK LOCKER SENSOR SUPPLY 3 T527 18YL/TN REAR LOCKER SENSOR SENSE 4 T528 16YL/GY REAR LOCKER RETURN Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Locations > Module-Axle Disconnect-Front > Page 8762 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front Solenoid: Diagrams Module-Axle Disconnect-Front Component ID: 202 Component : MODULE-AXLE DISCONNECT-FRONT Connector: Name : MODULE-AXLE DISCONNECT-FRONT Color : DK. GRAY # of pins : 4 Qualifier : (LD 4WD) Pin Circuit Description 1 Z906 20BK GROUND 2 G304 20VT/DB FRONT AXLE LOCK CONTROL 3 A880 20DB/RD FUSED B(+) 4 G303 20VT/DG FRONT AXLE LOCK SIGNAL Component Location - 35 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8765 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8766 Solenoid: Diagrams Solenoid-Locker-Front Component ID: 457 Component : SOLENOID-LOCKER-FRONT Connector: Name : SOLENOID-LOCKER-FRONT Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T520 16YL/OR FRONT LOCKER SOURCE 2 T521 18YL/BK LOCKER SENSOR SUPPLY 3 T522 18YL/LB FRONT LOCKER SENSOR SENSE 4 T524 16YL/LG FRONT LOCKER RETURN Component Location - 36 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8767 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8768 Solenoid: Diagrams Solenoid-Locker-Rear Component ID: 458 Component : SOLENOID-LOCKER-REAR Connector: Name : SOLENOID-LOCKER-REAR Color : BLACK # of pins : 4 Qualifier : (POWER WAGON) Pin Circuit Description 1 T526 16YL/WT REAR LOCKER SOURCE 2 T523 18YL/BK LOCKER SENSOR SUPPLY 3 T527 18YL/TN REAR LOCKER SENSOR SENSE 4 T528 16YL/GY REAR LOCKER RETURN Component Location - 70 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential Lock > Component Information > Diagrams > Module-Axle Disconnect-Front > Page 8769 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 8774 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications CORPORATE AXLES Front Axle C205F OPEN ................................................................................. .................................................................................................. 1.6L (56 oz) Front Axle C200F OPEN ..................................................................................................................... .................................................... 1.7L (57.5 ounces) Front Axle C200FE ANTI-SPIN .............................................................................................................................................................. 1.7L (57.5 ounces) Friction Modifier .................................................................................................... ................................................................................ 4.0 ounces (118 ml) Rear Axle 8.25 OPEN .......................................................................................................................... .................................................... 2.08L (4.4 ounces) Rear Axle 8.25 ANTI-SPIN .................................................................................................................. ...................................................... 2.1L (72 ounces) Friction Modifier ................................................ .................................................................................................................................... 4.0 ounces (118 ml) Rear Axle 9.25 OPEN .......................................................................................................................... ....................................................... 2.2L (74 ounces) Rear Axle 9.25 ANTI-SPIN .................................................................................................................. ...................................................... 2.1L (72 ounces) Friction Modifier ................................................ .................................................................................................................................... 4.0 ounces (118 ml) Rear Axle C213R OPEN ..................................................................................................................... ...................................................... 2.07L (70 ounces) Rear Axle C213RE ANTI-SPIN ......................................................................................................................................................... 2.24L (75.5 ounces) Friction Modifier .................................................................................................. .................................................................................. 4.0 ounces (118 ml) DANA AXLES Front Axle 186 FBI OPEN ............................................................................................ .................................................................................... 1.0L (2.1 Pt) Front Axle 186 FIA OPEN ................................................................................................................... ........................................................... 1.24L (2.6 Pt) Front Axle 216 FBI ANTI-SPIN ............................................................................................................ ........................................................... 1.3L (2.7 Pt) Rear Axle 226 RBI OPEN .................................................................................................................... ......................................................... 2.25L (4.75 Pt) Rear Axle 226 RBI ANTI-SPIN ............................................................................................................ ........................................................ 2.25L (4.75 Pt) Friction Modifier ................................................. ........................................................................................................................................... 0.1 ml (3.4 oz) Rear Axle 226 RIA ANTI-SPIN ............................................................................................................ ....................................................................... 1.35L Rear Axle 302 RBI OPEN .................................................................................................................... .......................................................................... 6.6L Rear Axle 302 RBI ANTI-SPIN ............................................................................................................ ......................................................................... 6.6L AMERICAN AXLES Front Axle 9.25 OPEN ........................................................................................ ........................................................................................................... 2.2L Front Axle 9.25 ANTI-SPIN ................................................................................................................. ......................................................................... 2.0L Rear Axle 10.5 OPEN .......................................................................................................................... ........................................................................... 2.5L Rear Axle 10.5 ANTI-SPIN .................................................................................................................. .......................................................................... 2.5L Rear Axle 11.5 OPEN .......................................................................................................................... ........................................................................... 4.2L Rear Axle 11.5 ANTI-SPIN .................................................................................................................. .......................................................................... 4.0L MAGNA AXLES FRONT AXLE 275 FBI OPEN .................................................................................. .................................................................................................... 5.1L Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 8777 Fluid - Differential: Fluid Type Specifications Front and Rear Axles .......................................................................... Synthetic GL-5 SAE 75W-90. 2500/3500 axles do not require limited slip additive. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal Differential Output Shaft Bearing: Service and Repair Removal REMOVAL 1. Remove half shaft from disconnect side of the axle. 2. Remove disconnect actuator wiring connector. 3. Remove disconnect actuator (1) bolts (2) and remove actuator from disconnect pocket. 4. Remove O-ring (1) and snap ring (2) from output shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8783 5. Remove disconnect seal (1) bolts (2). 6. Remove output shaft (1) and disconnect seal (2) with Remover 8420A (3) and Slide Hammer C-3752. 7. Slide disconnect collar (1) from intermediate shaft (2) and remove through disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8784 8. Remove differential cover. 9. Drive intermediate shaft (1) out of side gear with a hammer and brass punch (2). 10. Remove intermediate shaft (1) from disconnect pocket (2). 11. Install Puller 9766 (1) in intermediate shaft bearing (2) then tighten nut (3) to expand tool in bearing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8785 12. Tighten puller (1) nut (2) to remove intermediate shaft bearing from disconnect pocket. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8786 Differential Output Shaft Bearing: Service and Repair Installation INSTALLATION 1. Install intermediate shaft bearing (1) with Installer 9767 (2) and Handle C-4171. CAUTION: Bearing must be installed with lettering facing outwards. Failure to follow these instructions will damage the bearing. 2. Install new intermediate shaft snap ring. 3. Install intermediate shaft (1) through disconnect pocket (2) and verify intermediate shaft snap ring is seated in side gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8787 4. Install disconnect collar (1) through disconnect pocket onto intermediate shaft (2). 5. Position disconnect collar (1) on intermediate shaft (2) in 2WD position. 6. Verify output shaft bearing cup (1) is seated in disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8788 7. Install output shaft (1) in disconnect pocket (2). 8. Install disconnect seal (1) on output shaft (2). 9. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins MD998412 (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8789 10. Install disconnect seal (1) in disconnect pocket with Installer 6761 (2) and a hammer. 11. Install disconnect seal (1) bolts (2) and tighten to 28 Nm (21 ft. lbs.). 12. Install output shaft O-ring (1) and snap ring (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8790 13. Clean actuator (1) sealing surface and install new gasket (2) if necessary. 14. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket. 15. Install disconnect actuator (1) bolts (2) and tighten to 27 Nm (20 ft. lbs.). 16. Install disconnect actuator wiring connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Removal > Page 8791 17. Install differential cover and fill differential to specification. 18. Install half shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD Seals and Gaskets: Service and Repair Front Axle - C205FD Removal REMOVAL 1. Remove half shaft from disconnect side of the axle. 2. Remove O-ring (1) and snap ring (2) from the output shaft. 3. Remove disconnect seal (1) bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8796 4. Remove output shaft and disconnect seal (1) with Remover 8420A (2) and Slide Hammer C-3752. Installation INSTALLATION 1. Verify output shaft bearing cup (1) is seated in disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8797 2. Install output shaft (1) in disconnect pocket (2). 3. Install disconnect seal (1) on output shaft (2). 4. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins MD998412 (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8798 5. Install disconnect seal (1) in disconnect pocket with Installer 6761(2) and a hammer. 6. Install disconnect seal (1) bolts (2) and tighten to 28 Nm (21 ft. lbs.). 7. Install output shaft O-ring (1) and snap ring (2). 8. Install half shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8799 9. Verify differential fluid level and add fluid if necessary. Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. 5. Remove axle shaft seal with a seal puller. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8800 1. Wipe axle shaft tube bore clean. 2. Install new axle shaft seal with Installer 8694 (1). 3. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 4. Install o-ring (1) and snap ring (2) on axle shaft (3). 5. Install half shaft. 6. Verify differential fluid level and add fluid if necessary. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8801 1. With axle in 2WD remove front propeller shaft and left half shaft. 2. Rotate pinion gear three or four times and verify pinion rotates smoothly. 3. Record pinion torque to rotate with an inch pound torque wrench (2), for installation reference. 4. Position Holder 6719 against the companion flange (1) and install a four bolts and washers into the threaded holes and tighten the bolts. 5. Remove pinion nut. 6. Mark a line across the pinion shaft and flange for installation reference. 7. Remove companion flange with (1) Remover C-452 (2). 8. Remove pinion seal with a seal puller. Installation INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8802 2. Install seal with Installer 8695 (2) and Handle C-4171 (1). 3. Install flange on the pinion shaft with the reference marks aligned. 4. Install companion flange onto the pinion with Installer C-3718 and Holder 6719A. 5. Position holder (2) against the companion flange and install four bolts and washers into the threaded holes. Tighten the bolt and washer so that the holder is held to the flange. 6. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play CAUTION: Do not exceed 271 Nm (200 ft. lbs.) the minimum tightening torque when installing the companion flange at this point. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instruction will damage the axle. 7. Measure pinion Torque To Rotate with an inch pound torque wrench (2). Pinion Torque To Rotate should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). 8. If rotating torque is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion Torque To Rotate is achieved. CAUTION: If maximum tightening torque 475 Nm (350 ft. lbs.) is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Failure to follow these instruction will damage the axle. 9. Install propeller shaft and half shafts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8803 Seals and Gaskets: Service and Repair Front Axle - 9 1/4 AA Removal REMOVAL 1. Remove hub bearings and axle shafts. 2. Remove differential from differential housing (2). 3. Remove differential bearing adjusters (1). 4. Remove axle seals (2) located behind adjusters with Receiver 8498 and Extractor 6310. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8804 5. Install Receiver 8498 (1) into the adjuster bore. 6. Install Extractor Rod 6310 with Extractor Foot 6310-9 (2) through the receiver and axle seal. 7. Install Extractor Plate 6310-2 and Nut 6310-7 (2) on the extractor rod (1). 8. Tighten nut (2) on extractor rod (1) to pull seal into the receiver. Installation INSTALLATION 1. Install axle seal on Installer Cups 8885-2 (1) (3) and position cups with seals into the housing. NOTE: Seals are installed with the axle guide facing outward. 2. Install Turnbuckle 8885-1(2) into installer cups and expand the turnbuckle until the seals bottom out in the housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8805 3. Install adjuster (1) into the differential housing (2). 4. Install differential in housing. 5. Install axle shaft and hub bearings. Removal REMOVAL 1. Mark propeller shaft and pinion flange (1) for installation reference. 2. Remove propeller shaft. 3. Remove hub bearings and axle shafts. 4. Rotate pinion gear three or four times. 5. Record pinion torque to rotate (1) with an inch pound torque wrench (2) for installation reference. 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8806 7. Mark a line across the pinion shaft and flange for installation reference. 8. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 9. Remove pinion seal with a seal puller. Installation INSTALLATION 1. Install new pinion seal with Installer 8882 (2) and Handle C-4171 (1). 2. Apply a light coat of teflon thread sealant, to pinion flange splines. 3. Install flange on the pinion shaft with the reference marks aligned. 4. Lightly tap pinion flange onto the pinion, until a few threads are showing. 5. Install flange washer and new pinion nut. 6. Hold flange (1) with Flange Wrench 8979 (2) and tighten pinion nut until pinion end play is taken up. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8807 7. Rotate pinion flange (1) several times to seat bearings. 8. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.40-0.57 Nm (3-5 in. lbs.). 9. If torque to rotating is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. 10. Rotate pinion several times then verify pinion torque to rotate again. 11. Install axle shafts and hub bearings. 12. Install propeller shaft with reference marks aligned. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8808 Seals and Gaskets: Service and Repair Front Axle - 275FBI Removal REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove brake caliper, caliper adapter, hub extension, rotor and ABS sensor. 3. Bend axle shaft hub nut (1) collar out of the axle keyway. 4. Remove axle shaft hub nut (1). 5. Remove four hub bearing bolts (1) from the back of the steering knuckle. 6. Remove hub bearing from the steering knuckle. 7. Remove axle shaft (1) with hub bearing shim (2) from axle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8809 8. Remove axle seal (1) from axle yoke with seal puller (2). Installation INSTALLATION 1. Install axle shaft seal into axle yoke with Installer 10011 (1) Handle C-4171 (2). 2. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore. 3. Install axle shaft (1) with hub bearing shim (2) into the axle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8810 4. Install hub bearing in the knuckle. 5. Install hub bearing bolts (1) and tighten to 200 Nm (147 ft. lbs.). 6. Install ABS sensor, brake rotor (1), hub extension (2), caliper adapter and caliper. 7. Install axle hub nut (3) and tighten nut to 330 Nm (243 ft. lbs.). 8. Bend axle shaft hub nut (3) collar into axle keyway with a hammer and punch. Removal REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove propeller shaft. 3. Bend pinion flange (1) nut (2) collar lock out of the pinion shaft keyway. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8811 4. Hold pinion flange (1) with Holder C-3281 (2) and remove pinion flange nut. 5. Mark a line across the pinion shaft and flange for installation reference. 6. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 7. Remove pinion seal with a seal puller. Installation INSTALLATION 1. Install new pinion seal with Installer 10069 (1). 2. Apply a light coat of teflon thread sealant, to pinion flange splines. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8812 3. Position flange on pinion shaft with reference marks aligned. 4. Install pinion flange (1) new pinion nut. 5. Hold flange with Holder C-3281 (2) and tighten pinion nut to 500 Nm (369 ft. lbs.). 6. Bend pinion flange (1) nut (2) collar into pinion keyway with a hammer and punch. 7. Install propeller shaft with reference marks aligned. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8813 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a seal puller. Installation INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Handle C-4735. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8814 1. Mark universal joint, companion flange and pinion shaft for installation reference. 2. Remove propeller shaft from the companion flange. 3. Remove the brake rotors to prevent any drag. 4. Rotate companion flange three or four times. 5. Record pinion torque to rotating (1) with an inch pound torque wrench (2). 6. Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A against the companion flange and install and tighten two bolts and washers into the remaining holes. 7. Hold the companion flange with Holder 6719A and remove pinion nut and washer. 8. Mark a line across the pinion shaft and flange for installation reference. 9. Remove companion flange with Puller C-452 (2). 10. Remove pinion seal with seal puller or slide-hammer mounted screw. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8815 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install new pinion seal (3) with Handle C-4735 and Installer C-4076-B (1). 3. Install flange on the pinion shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719A (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719A. 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. 8. Hold companion flange with Holder 6719A (2) and tighten pinion nut with a torque wrench (3) to 285 Nm (210 ft. lbs.). NOTE: Do not exceed the minimum torque 285 Nm (210 ft. lbs.) when installing the pinion nut at this point. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8816 9. Rotate pinion several times to ensure pinion bearings are seated. 10. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). If pinion torque to rotate is low, tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotating is achieved. CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions will result in damage to the axle. 11. Install propeller shaft. 12. Install rear brake rotors components. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8817 Seals and Gaskets: Service and Repair Removal REMOVAL 1. Remove half shaft from disconnect side of the axle. 2. Remove O-ring (1) and snap ring (2) from the output shaft. 3. Remove disconnect seal (1) bolts (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8818 4. Remove output shaft and disconnect seal (1) with Remover 8420A (2) and Slide Hammer C-3752. Installation INSTALLATION 1. Verify output shaft bearing cup (1) is seated in disconnect pocket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8819 2. Install output shaft (1) in disconnect pocket (2). 3. Install disconnect seal (1) on output shaft (2). 4. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins MD998412 (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8820 5. Install disconnect seal (1) in disconnect pocket with Installer 6761(2) and a hammer. 6. Install disconnect seal (1) bolts (2) and tighten to 28 Nm (21 ft. lbs.). 7. Install output shaft O-ring (1) and snap ring (2). 8. Install half shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8821 9. Verify differential fluid level and add fluid if necessary. Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. 5. Remove axle shaft seal with a seal puller. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8822 1. Wipe axle shaft tube bore clean. 2. Install new axle shaft seal with Installer 8694 (1). 3. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 4. Install o-ring (1) and snap ring (2) on axle shaft (3). 5. Install half shaft. 6. Verify differential fluid level and add fluid if necessary. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8823 1. With axle in 2WD remove front propeller shaft and left half shaft. 2. Rotate pinion gear three or four times and verify pinion rotates smoothly. 3. Record pinion torque to rotate with an inch pound torque wrench (2), for installation reference. 4. Position Holder 6719 against the companion flange (1) and install a four bolts and washers into the threaded holes and tighten the bolts. 5. Remove pinion nut. 6. Mark a line across the pinion shaft and flange for installation reference. 7. Remove companion flange with (1) Remover C-452 (2). 8. Remove pinion seal with a seal puller. Installation INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8824 2. Install seal with Installer 8695 (2) and Handle C-4171 (1). 3. Install flange on the pinion shaft with the reference marks aligned. 4. Install companion flange onto the pinion with Installer C-3718 and Holder 6719A. 5. Position holder (2) against the companion flange and install four bolts and washers into the threaded holes. Tighten the bolt and washer so that the holder is held to the flange. 6. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play CAUTION: Do not exceed 271 Nm (200 ft. lbs.) the minimum tightening torque when installing the companion flange at this point. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instruction will damage the axle. 7. Measure pinion Torque To Rotate with an inch pound torque wrench (2). Pinion Torque To Rotate should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). 8. If rotating torque is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion Torque To Rotate is achieved. CAUTION: If maximum tightening torque 475 Nm (350 ft. lbs.) is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Failure to follow these instruction will damage the axle. 9. Install propeller shaft and half shafts. Removal Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8825 REMOVAL 1. Remove hub bearings and axle shafts. 2. Remove differential from differential housing (2). 3. Remove differential bearing adjusters (1). 4. Remove axle seals (2) located behind adjusters with Receiver 8498 and Extractor 6310. 5. Install Receiver 8498 (1) into the adjuster bore. 6. Install Extractor Rod 6310 with Extractor Foot 6310-9 (2) through the receiver and axle seal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8826 7. Install Extractor Plate 6310-2 and Nut 6310-7 (2) on the extractor rod (1). 8. Tighten nut (2) on extractor rod (1) to pull seal into the receiver. Installation INSTALLATION 1. Install axle seal on Installer Cups 8885-2 (1) (3) and position cups with seals into the housing. NOTE: Seals are installed with the axle guide facing outward. 2. Install Turnbuckle 8885-1(2) into installer cups and expand the turnbuckle until the seals bottom out in the housing. 3. Install adjuster (1) into the differential housing (2). 4. Install differential in housing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8827 5. Install axle shaft and hub bearings. Removal REMOVAL 1. Mark propeller shaft and pinion flange (1) for installation reference. 2. Remove propeller shaft. 3. Remove hub bearings and axle shafts. 4. Rotate pinion gear three or four times. 5. Record pinion torque to rotate (1) with an inch pound torque wrench (2) for installation reference. 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer. 7. Mark a line across the pinion shaft and flange for installation reference. 8. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 9. Remove pinion seal with a seal puller. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8828 INSTALLATION 1. Install new pinion seal with Installer 8882 (2) and Handle C-4171 (1). 2. Apply a light coat of teflon thread sealant, to pinion flange splines. 3. Install flange on the pinion shaft with the reference marks aligned. 4. Lightly tap pinion flange onto the pinion, until a few threads are showing. 5. Install flange washer and new pinion nut. 6. Hold flange (1) with Flange Wrench 8979 (2) and tighten pinion nut until pinion end play is taken up. 7. Rotate pinion flange (1) several times to seat bearings. 8. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.40-0.57 Nm (3-5 in. lbs.). 9. If torque to rotating is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. 10. Rotate pinion several times then verify pinion torque to rotate again. 11. Install axle shafts and hub bearings. 12. Install propeller shaft with reference marks aligned. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8829 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove brake caliper, caliper adapter, hub extension, rotor and ABS sensor. 3. Bend axle shaft hub nut (1) collar out of the axle keyway. 4. Remove axle shaft hub nut (1). 5. Remove four hub bearing bolts (1) from the back of the steering knuckle. 6. Remove hub bearing from the steering knuckle. 7. Remove axle shaft (1) with hub bearing shim (2) from axle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8830 8. Remove axle seal (1) from axle yoke with seal puller (2). Installation INSTALLATION 1. Install axle shaft seal into axle yoke with Installer 10011 (1) Handle C-4171 (2). 2. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore. 3. Install axle shaft (1) with hub bearing shim (2) into the axle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8831 4. Install hub bearing in the knuckle. 5. Install hub bearing bolts (1) and tighten to 200 Nm (147 ft. lbs.). 6. Install ABS sensor, brake rotor (1), hub extension (2), caliper adapter and caliper. 7. Install axle hub nut (3) and tighten nut to 330 Nm (243 ft. lbs.). 8. Bend axle shaft hub nut (3) collar into axle keyway with a hammer and punch. Removal REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove propeller shaft. 3. Bend pinion flange (1) nut (2) collar lock out of the pinion shaft keyway. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8832 4. Hold pinion flange (1) with Holder C-3281 (2) and remove pinion flange nut. 5. Mark a line across the pinion shaft and flange for installation reference. 6. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 7. Remove pinion seal with a seal puller. Installation INSTALLATION 1. Install new pinion seal with Installer 10069 (1). 2. Apply a light coat of teflon thread sealant, to pinion flange splines. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8833 3. Position flange on pinion shaft with reference marks aligned. 4. Install pinion flange (1) new pinion nut. 5. Hold flange with Holder C-3281 (2) and tighten pinion nut to 500 Nm (369 ft. lbs.). 6. Bend pinion flange (1) nut (2) collar into pinion keyway with a hammer and punch. 7. Install propeller shaft with reference marks aligned. Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a seal puller. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8834 INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Handle C-4735. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Removal REMOVAL 1. Mark universal joint, companion flange and pinion shaft for installation reference. 2. Remove propeller shaft from the companion flange. 3. Remove the brake rotors to prevent any drag. 4. Rotate companion flange three or four times. 5. Record pinion torque to rotating (1) with an inch pound torque wrench (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8835 6. Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A against the companion flange and install and tighten two bolts and washers into the remaining holes. 7. Hold the companion flange with Holder 6719A and remove pinion nut and washer. 8. Mark a line across the pinion shaft and flange for installation reference. 9. Remove companion flange with Puller C-452 (2). 10. Remove pinion seal with seal puller or slide-hammer mounted screw. Installation INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install new pinion seal (3) with Handle C-4735 and Installer C-4076-B (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8836 3. Install flange on the pinion shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719A (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719A. 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. 8. Hold companion flange with Holder 6719A (2) and tighten pinion nut with a torque wrench (3) to 285 Nm (210 ft. lbs.). NOTE: Do not exceed the minimum torque 285 Nm (210 ft. lbs.) when installing the pinion nut at this point. 9. Rotate pinion several times to ensure pinion bearings are seated. 10. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). If pinion torque to rotate is low, tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotating is achieved. CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions will result in damage to the axle. 11. Install propeller shaft. 12. Install rear brake rotors components. Removal Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8837 REMOVAL 1. Remove axle shafts. 2. Mark propeller shaft and pinion flange for installation reference and remove shaft. 3. Rotate pinion gear three or four times. 4. Record pinion torque to rotate (1) with an inch pound torque wrench (2). 5. Hold pinion flange (1) with Wrench 8979 (2) and remove pinion flange nut and washer. 6. Mark a line across the pinion shaft and flange for installation reference. 7. Remove pinion flange (1) with Puller 8992 (2). 8. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8838 1. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Install flange on the pinion shaft with the reference marks aligned. 4. Lightly tap the pinion flange onto the pinion until a few threads are showing. 5. Install flange washer and new pinion nut. 6. Hold flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 7. Rotate pinion several times to seat bearings. 8. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.40-0.57 Nm (3-5 in. lbs.). 9. If torque to rotating is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. 10. Rotate pinion several times then verify pinion torque to rotate again. 11. Install axle shafts. 12. Install propeller shaft with reference marks aligned. 13. Check and fill differential if necessary. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8839 1. Remove axle shafts. 2. Mark the propeller shaft and pinion flange for installation reference. 3. Remove propeller shaft. 4. Rotate pinion gear (1) three or four times. 5. Measure and record the amount of torque necessary to rotate the pinion gear with an inch pound torque wrench (2). 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut. 7. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 8. Remove pinion shaft seal with a seal puller or slide hammer mounted screw. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8840 1. Install new pinion seal with Handle C-4171 (1) and Installer 8896 (2). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) Torque To Rotate with an inch pound torque wrench (2) and compare it to recorded measurement. Tighten pinion nut in small increments, until pinion Torque To Rotate is 0.40-0.57 Nm (3-5 in. lbs.) greater than recorded measurement. 8. Rotate pinion several times then verify pinion Torque To Rotate again. 9. Install axle shafts. 10. Install propeller shaft with reference marks aligned. 11. Check differential fluid level. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8841 1. Remove propeller shaft. 2. Install Adapter 10054 (1) on pinion flange and bolt (2) in place. 3. Hold pinion flange with Holder 6719A (1) and Adapter 10054 (2). 4. Remove pinion nut with a torque multiplier (1) and ratchet (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8842 5. Bolt Puller 8992 (1) to Adapter 10054 and remove pinion flange. 6. Remove pinion seal with seal puller. Installation INSTALLATION 1. Install pinion seal in housing (2) with Installer 10055 (1). 2. Install pinion flange on pinion. 3. Install new pinion nut. 4. Install Adapter 10054 (1) on pinion flange and bolt (2) in place. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205FD > Page 8843 5. Hold pinion flange with Holder 6719A (1) and Adapter 10054 (2). 6. Tighten pinion nut to 937 Nm (689 ft. lbs.) with a torque multiplier (1) and torque wrench (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD Axle Bearing: Service and Repair Front Axle - C205FD Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2) (3) Collar 8420-3 (4) and Slide Hammer C-3752. 5. Remove axle shaft seal with a seal puller. 6. Install axle shaft bearing Remover C-4660-A (3) in the bearing (1). Then tighten the nut (2) to spread remover in the bearing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8849 7. Install bearing remove cup (1) bearing (2) and nut (3). Tighten nut (3) to draw the bearing out. Installation INSTALLATION 1. Wipe axle shaft bearing bore clean. 2. Install axle shaft bearing with Installer 5063 (1) and Handle C-4171 (2). CAUTION: Bearing must be installer with lettering facing outwards. Failure to follow these instructions will damage the bearing. 3. Install a new axle shaft seal with Installer 8694 (1). 4. Lubricate seal lip with gear lubricant. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8850 5. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 6. Install axle shaft (3) O-ring (1) and snap ring (2). 7. Install half shaft. 8. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8851 Axle Bearing: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. 3. Remove axle shaft bearing with Bearing Remover 6310 (2) (3) (4) (5) and Foot 6310-9 (7). Installation INSTALLATION 1. Wipe axle tube bore clean and remove any old sealer or burrs from the tube. 2. Install axle shaft bearing with Installer C-4198 and Handle C-4171. Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat lip of the new axle seal with axle lubricant and install with Installer C-4076-B and Handle C-4735. 4. Install the axle shaft (1). 5. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8852 Axle Bearing: Service and Repair Rear Axle - 10 1/2 AA Removal REMOVAL 1. Remove axle shaft flange bolts and remove axle shaft. 2. Remove retainer ring (1) from axle shaft tube. 3. Remove hub bearing nut (1) locking key (2) from axle tube (3). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. 6. Pry out hub bearing seal from the back of the hub. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8853 NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed with pry bar (1). 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. Installation INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C-4171. 2. Install inner hub bearing cup with Installer 8962 and Handle C-4171. 3. Pack bearings with the appropriate grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C-4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and torque wrench (2) to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. End play should be 0.025-0.25 mm (0.001-0.010 in.). 8. Install retainer ring (1) with ring end in the key slot (2). 9. Install new axle shaft gasket and install axle shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8854 Axle Bearing: Service and Repair Rear Axle - 11 1/2 AA Removal REMOVAL 1. Remove axle shaft flange bolts and remove shaft. 2. Remove retainer ring (1) from the axle shaft tube. 3. Remove hub bearing nut (1) locking key (2) form axle tube (3). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. 6. Pry out hub bearing seal from the back of the hub. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8855 NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed with a pry bar (1). 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. Installation INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C-4171. 2. Install inner hub bearing cup with Installer 8153 and Handle C-4171. 3. Pack bearings with the appropriate wheel bearing grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C-4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and tighten with torque wrench (2) to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. NOTE: End play should be 0.025-0.25 mm (0.01-0.001 in.) 8. Install retainer ring (1) with ring end in the key slot (2). 9. Install new axle shaft gasket and install the axle shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8856 Axle Bearing: Service and Repair Rear Axle - 302RBI Removal REMOVAL 1. Remove axle bolts (1) from axle flange (2). 2. Remove axle shaft (1) from axle. 3. With Socket 10051 (1) remove hub nut with integrated lock washer from hub (2) spindle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8857 4. Install hub/rotor Guide 10064 (1) into hub spindle (2). 5. Slide hub/rotor (1) with bearings off hub spindle and hub/rotor Guide 10064 (2). 6. Remove outer bearing (1) from hub (2). 7. Remove hub seal (1) from the back of the hub (2) with seal puller. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8858 8. Remove inner bearing (1) from hub (2). 9. Remove outer bearing cup (1) from hub (2) with a hammer and brass drift. 10. Remove inner bearing cup (1) from hub (2) with hammer and brass drift. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8859 1. Install outer hub bearing cup with Installer 10052 (1) and Handle C-4171 (2). 2. Install inner hub bearing cup with Installer 10049 (1) and Handle C-4171 (2). 3. Lubricate and install inner hub bearing (1) into hub (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8860 4. Install hub seal with Installer 10053 (1) and Handle C-4171 (2). 5. Lubricate and install outer hub bearing (1) into hub (2). 6. Install hub/rotor Guide 10064 (1) into the axle spindle (2). 7. Install hub/rotor (1) over Guide 10064 (2) onto the axle spindle. CAUTION: Never support hub with just the inner bearing and seal. Failure to follow these instruction will result in damaging the hub seal. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8861 8. Remove Guide 10064 (1) from axle spindle (2). 9. Install hub bearing nut (1) with integrated lock washer (2). NOTE: Integrated lock washer tab must be aligned with the spindle keyway. 10. Tighten hub (1) nut with Socket 10051 (2) to 95 Nm (70 ft. lbs.) while rotating the hub. Then back off nut 90 degrees and retighten nut to 41 Nm (30 ft. lbs.). NOTE: This will set hub to zero end-play. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8862 11. Install new O-ring (1) on axle flange (2). 12. Install axle shaft (1) into the hub (2) and axle. 13. Install axle bolts (1) through axle flange (2) and tighten to 133 Nm (98 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8863 14. Remove fill plug (1), from right side of carrier. 15. With axle level, fill carrier with lubricant to the bottom of the fill plug hole. 16. Install fill plug (1) and tighten to 68 Nm (50 ft. lbs.). WHEEL HUB OIL FILL CAUTION: Wheel hub cavities must be filled with lubricate before using axle. Failure to follow these instruction will result in hub bearing damage. 1. Raise right end (1) of axle six inches. Hold in this position for one minute to fill left hub (2) with lubricate. 2. Lower the axle. 3. Raise left end (1) of axle six inches. Hold in this position for one minute to fill right hub (2) with lubricate. 4. Lower the axle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205FD > Page 8864 5. Remove fill plug (1), from right side of carrier. 6. With axle level, fill carrier with lubricant to the bottom of the fill plug hole. NOTE: Axle will require approximately 1.18 L (40 oz.) of additional lubricant. 7. Install fill plug (1) and tighten to 68 Nm (50 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD Axle Shaft: Service and Repair Front Axle - C205FD Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8870 1. Lubricate bearing bore and seal lip with gear lubricant. 2. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 3. Install o-ring (1) and snap ring (2) on axle shaft (3). 4. Install half shaft. 5. Verify differential fluid level and add fluid if necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8871 Axle Shaft: Service and Repair Front Axle - 9 1/4 AA Removal REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove brake caliper, rotor and ABS wheel speed sensor if equipped. 3. Remove axle shaft (2) cotter pin (3), hub nut (1) and washer. 4. Remove four hub bearing bolts (2) from the back of the steering knuckle. 5. Remove hub bearing from the steering knuckle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8872 6. Remove axle shaft (2) from steering knuckle (1) and axle housing. Installation INSTALLATION 1. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore. 2. Install axle shaft (2) through the steering knuckle (3) and into the differential side gears. 3. Install hub bearing in the knuckle. 4. Install hub bearing bolts (2) and tighten to 202 Nm (149 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8873 5. Install ABS wheel speed sensor, brake rotor and caliper. 6. Install axle (2) washer and nut (1). Tighten axle nut to 179 Nm (132 ft. lbs.). 7. Rotate axle several 5 to 10 times to seat the wheel bearing. 8. Tighten axle nut (1) to final torque of 356 Nm (263 ft. lbs.). 9. Align nut to next cotter pin hole and install new cotter pin (3). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8874 Axle Shaft: Service and Repair Front Axle - 275FBI Removal REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove brake caliper, caliper adapter, hub extension, rotor and ABS sensor. 3. Bend axle shaft hub nut (1) collar out of the axle keyway. 4. Remove axle shaft hub nut (1). 5. Remove four hub bearing bolts (1) from the back of the steering knuckle. 6. Remove hub bearing from the steering knuckle. 7. Remove axle shaft (1) with hub bearing shim (2) from axle. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8875 1. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore. 2. Install axle shaft (1) with hub bearing shim (2) into the axle. 3. Install hub bearing in the knuckle. 4. Install hub bearing bolts (1) and tighten to 200 Nm (147 ft. lbs.). 5. Install ABS sensor, brake rotor (1), hub extension (2), caliper adapter and caliper. 6. Install axle hub nut (3) and tighten nut to 330 Nm (243 ft. lbs.). 7. Bend axle shaft hub nut (3) collar into axle keyway with a hammer and punch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8876 Axle Shaft: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove wheel and tire assembly. 3. Remove brake caliper (3), adapter (2) and rotor (1). 4. Remove differential housing cover and drain lubricant. 5. Rotate differential case so pinion mate shaft lock screw is accessible. Remove lock screw (1) and pinion mate shaft (2) from differential case. 6. Push axle shaft (2) inward and remove C-lock (1) from the axle shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8877 7. Remove axle shaft (1) carefully to prevent damage to the shaft bearing and seal in the axle tube. Installation INSTALLATION 1. Lubricate bearing bore and seal lip with gear lubricant. 2. Install axle shaft and engage into side gear splines. NOTE: Use care to prevent shaft splines from damaging axle shaft seal. 3. Insert C-lock (1) in end of axle shaft (2) then push axle shaft outward to seat C-lock in side gear (3). 4. Insert pinion shaft into differential case and through thrust washers and differential pinions. 5. Align hole in pinion mate shaft (2) with hole in the differential case and install lock screw (1) with Loctite(R) on the threads. Tighten lock screw to 11 Nm (8 ft. lbs.). 6. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. 7. Install brake rotor, caliper adapter and caliper. 8. Install wheel and tire. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8878 Axle Shaft: Service and Repair Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove O-ring (1) and snap ring (2) from axle shaft (3). 4. Remove axle with Remove 8420A (2,3,4) and Slide Hammer C-3752. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8879 1. Lubricate bearing bore and seal lip with gear lubricant. 2. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear. 3. Install o-ring (1) and snap ring (2) on axle shaft (3). 4. Install half shaft. 5. Verify differential fluid level and add fluid if necessary. Removal REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove brake caliper, rotor and ABS wheel speed sensor if equipped. 3. Remove axle shaft (2) cotter pin (3), hub nut (1) and washer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8880 4. Remove four hub bearing bolts (2) from the back of the steering knuckle. 5. Remove hub bearing from the steering knuckle. 6. Remove axle shaft (2) from steering knuckle (1) and axle housing. Installation INSTALLATION 1. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore. 2. Install axle shaft (2) through the steering knuckle (3) and into the differential side gears. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8881 3. Install hub bearing in the knuckle. 4. Install hub bearing bolts (2) and tighten to 202 Nm (149 ft. lbs.). 5. Install ABS wheel speed sensor, brake rotor and caliper. 6. Install axle (2) washer and nut (1). Tighten axle nut to 179 Nm (132 ft. lbs.). 7. Rotate axle several 5 to 10 times to seat the wheel bearing. 8. Tighten axle nut (1) to final torque of 356 Nm (263 ft. lbs.). 9. Align nut to next cotter pin hole and install new cotter pin (3). Removal REMOVAL 1. With the vehicle in neutral, position vehicle on hoist. 2. Remove brake caliper, caliper adapter, hub extension, rotor and ABS sensor. 3. Bend axle shaft hub nut (1) collar out of the axle keyway. 4. Remove axle shaft hub nut (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8882 5. Remove four hub bearing bolts (1) from the back of the steering knuckle. 6. Remove hub bearing from the steering knuckle. 7. Remove axle shaft (1) with hub bearing shim (2) from axle. Installation INSTALLATION 1. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore. 2. Install axle shaft (1) with hub bearing shim (2) into the axle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8883 3. Install hub bearing in the knuckle. 4. Install hub bearing bolts (1) and tighten to 200 Nm (147 ft. lbs.). 5. Install ABS sensor, brake rotor (1), hub extension (2), caliper adapter and caliper. 6. Install axle hub nut (3) and tighten nut to 330 Nm (243 ft. lbs.). 7. Bend axle shaft hub nut (3) collar into axle keyway with a hammer and punch. Removal REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove wheel and tire assembly. 3. Remove brake caliper (3), adapter (2) and rotor (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8884 4. Remove differential housing cover and drain lubricant. 5. Rotate differential case so pinion mate shaft lock screw is accessible. Remove lock screw (1) and pinion mate shaft (2) from differential case. 6. Push axle shaft (2) inward and remove C-lock (1) from the axle shaft. 7. Remove axle shaft (1) carefully to prevent damage to the shaft bearing and seal in the axle tube. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8885 1. Lubricate bearing bore and seal lip with gear lubricant. 2. Install axle shaft and engage into side gear splines. NOTE: Use care to prevent shaft splines from damaging axle shaft seal. 3. Insert C-lock (1) in end of axle shaft (2) then push axle shaft outward to seat C-lock in side gear (3). 4. Insert pinion shaft into differential case and through thrust washers and differential pinions. 5. Align hole in pinion mate shaft (2) with hole in the differential case and install lock screw (1) with Loctite(R) on the threads. Tighten lock screw to 11 Nm (8 ft. lbs.). 6. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. 7. Install brake rotor, caliper adapter and caliper. 8. Install wheel and tire. Removal REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8886 INSTALLATION NOTE: Axle flange bolts must be replaced or cleaned existing bolts apply Mopar(TM) Lock N' Seal or Loctite(R) 242 on the threads. 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm (95 ft. lbs.). Removal REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. Installation INSTALLATION NOTE: Axle flange bolts must be replaced or use Mopar(TM) Lock N' Seal or Loctite(R) 242 on cleaned existing bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8887 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm ( 95 ft. lbs.). Removal REMOVAL 1. Remove axle shaft bolts (1) from axle flange (2). 2. Slide axle shaft (1) out of the axle. 3. Remove axle shaft O-ring (1) from axle flange (2). Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8888 1. Install new O-ring (1) on axle flange (2). 2. Slide axle shaft (1) into the axle. 3. Install bolts (1) in axle flange (2) and tighten to 133 Nm (98 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205FD > Page 8889 4. Remove fill plug (1), from right side of carrier. 5. With axle level, fill carrier with lubricant to the bottom of the fill plug hole. 6. Install fill plug (1) and tighten to 68 Nm (50 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer Constant Velocity Joint: Service and Repair CV Joint-Outer Removal REMOVAL 1. Clamp shaft in a vise (with soft jaws) and support C/V joint. CAUTION: Do not damage C/V housing or half shaft. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. 3. Slide the boot down the shaft. 4. Remove lubricant to expose the C/V joint snap ring (1). 5. Spread snap ring (1) and slide the joint off the shaft. 6. Slide boot off the shaft and discard old boot. 7. Mark alignment marks (1) on the inner race/hub (2), bearing cage (3) and housing with dabs of paint. 8. Clamp C/V joint in a vertical position in a soft jawed vise. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 8894 9. Press down one side of the bearing cage (3) to gain access to the ball at the opposite side. NOTE: If joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bearing cage with the drift. 10. Remove ball (4) from the bearing cage (3). 11. Repeat step above until all six balls are removed from the bearing cage. 12. Lift cage and inner race (2) upward and out from the housing (1). 13. Turn inner race 90° in the cage and rotate the inner race/hub out of the cage. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 8895 NOTE: If C/V joint is worn, replace entire C/V joint and boot. 1. Clean all C/V joint components and shaft. 2. Apply a light coat of grease supplied with the joint/boot to the C/V joint components before assembling them. 3. Align the inner race (1) cage (2) and housing according to the alignment reference marks. 4. Insert the inner race (1) into the cage (2) and rotate race into the cage. 5. Rotate the inner race/hub (2) in the cage. 6. Insert cage (2) into the housing. Rotate the cage 90° into the housing (3) so the large bearing hub counterbore is facing outwards. 7. Apply the grease supplied with the joint/boot to the ball races. Spread the grease equally between all the races. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 8896 8. Tilt inner race/hub (1) and cage (3) and install the balls(4). 9. Place new clamps onto new boot and slide boot onto the shaft to it's original position. 10. Apply the rest of grease to the C/V joint and boot. 11. Install the joint onto the shaft (2). Push the joint onto the shaft until the snap ring (1) seats in the groove (3). NOTE: Pull on the joint to verify the span ring has engaged. 12. Position the boot on the joint in it's original position. NOTE: Verify boot is not twisted and remove any excess air. 13. Secure both boot (5) clamps (2) (4) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until jaws of the tool are closed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 8897 Constant Velocity Joint: Service and Repair CV Joint-Inner Removal REMOVAL 1. Clamp shaft in vise (with soft jaws) and support C/V joint. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. CAUTION: Do not damage C/V housing or half shaft with cut-off wheel or grinder. 3. Remove housing (2) from the half shaft and slide boot (1) down shaft. 4. Remove housing bushing from the housing. 5. Remove tripod (2) snap ring (1). 6. Remove tripod (2) and boot from the half shaft. 7. Clean and inspect C/V components for excessive wear and damage. Replace the tripod as a unit only if necessary. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > CV Joint-Outer > Page 8898 INSTALLATION 1. Clean all C/V joint components and shaft. 2. Slide new boot (1) down the half shaft. 3. Install tripod (2) and tripod snap ring on the half shaft. 4. Pack grease supplied with the joint/boot into the housing and boot. 5. Coat tripod with supplied grease. 6. Install new bushing (1) onto the housing (2). 7. Insert the tripod and shaft in the housing. 8. Position the boot (2) on the housing (5) and shaft (4) in it's original position. NOTE: Verify boot is not twisted and remove any excess air. 9. Measure the distance from the end of the housing to the end of the boot on the shaft. This measurement should be 260 mm (10.25 in.). NOTE: If measurement is not correct, allow more or less air into the boot. 10. Secure both boot clamps (1) (3) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA Universal Joint: Service and Repair Front Axle - 9 1/4 AA Removal REMOVAL NOTE: Saturate bearing caps with penetrating oil prior to removal. 1. Remove axle shaft. 2. Remove bearing cap snap rings (1) from stub shaft yoke (2) bearing caps. 3. Position receiver/socket (2) and driver/socket (1) on stub shaft yoke (3) in press. Press bearing cup into receiver/socket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8903 4. Remove bearing cap (1) from stub shaft yoke (2). 5. Position receiver/socket (2) under stub shaft yoke (3) remaining bearing cup and driver/socket (1) on U-joint cross in press. Press bearing cup into receiver/socket (2) 6. Remove bearing cap (1) from stub shaft yoke (2). Then remove stub shaft from U-joint cross. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8904 7. Remove snap rings (1) from shaft yoke (2) bearing caps. 8. Position receiver/socket (2) and driver/socket (1) on shaft yoke (3) in press. Press bearing cup into receiver/socket (2). 9. Remove bearing cap (1) from shaft yoke (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8905 10. Position receiver/socket (2) under shaft yoke (3) remaining bearing cup and driver/socket (1) on U-joint cross in press. Press bearing cup into receiver/socket (2) 11. Remove bearing cap (1) from shaft yoke (2). Then remove U-joint cross from shaft yoke. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8906 CAUTION: Keep cross and bearing cap straight during installation. Failure to follow these instruction will result in damage. 1. Pack bearing caps 1/3 full of wheel bearing lubricant. Apply extreme pressure (EP), lithium-base lubricant to aid in installation. 2. Position cross (1) in the shaft yoke (2). 3. Tap bearing cap into the yoke bores far enough to position cross. 4. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8907 5. Press bearing cap into shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). 6. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. 7. Press bearing cap into shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8908 8. Install stub shaft yoke (1) on U-joint cross (2). 9. Tap fist bearing cap into the stub shaft yoke bore far enough to position cross. 10. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. 11. Press bearing cap into stub shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8909 12. Position receiver/socket (1) on stub shaft yoke and driver/socket (2) on bearing cap in press. 13. Press bearing cap into stub shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2). 14. Install axle shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8910 Universal Joint: Service and Repair Front Axle - 275FBI Removal REMOVAL 1. Remove bearing cap snap rings (1) from the axle yoke (2) and stub shaft yoke (3). NOTE: Saturate bearing caps with penetrating oil prior to removal. 2. Position receiver/socket (2) and driver/socket (1) on stub shaft yoke (3) in press. Press bearing cup into receiver/socket (2). 3. Remove bearing cap (1) from stub shaft yoke (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8911 4. Position receiver/socket (2) under stub shaft yoke (3) remaining bearing cup and driver/socket (1) on U-joint cross in press. Press bearing cup into receiver/socket (2) 5. Remove bearing cap (1) from stub shaft yoke (2). Then remove stub shaft from U-joint cross. 6. Position receiver/socket (2) and driver/socket (1) on shaft yoke (3) in press. Press bearing cup into receiver/socket (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8912 7. Remove bearing cap (1) from shaft yoke (2). 8. Position receiver/socket (2) under shaft yoke (3) remaining bearing cup and driver/socket (1) on U-joint cross in press. Press bearing cup into receiver/socket (2) 9. Remove bearing cap (1) from shaft yoke (2). Then remove U-joint cross from shaft yoke. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8913 CAUTION: Keep cross and bearing cap straight during installation. Failure to follow these instruction will result in damage. 1. Pack bearing caps 1/3 full of wheel bearing lubricant. Apply extreme pressure (EP), lithium-base lubricant to aid in installation. 2. Position cross (1) in the shaft yoke (2). 3. Tap bearing cap into the yoke bores far enough to position cross. 4. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press. 5. Press bearing cap into shaft yoke until bearing cap snap ring groove is visible and install snap ring. 6. Position receiver/socket (1) on shaft yoke (2) and driver/socket on bearing cap in press. 7. Press bearing cap into shaft yoke until bearing cap snap ring groove is visible and install snap ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Universal Joint, Half Shaft/Short Shaft > Component Information > Service and Repair > Front Axle - 9 1/4 AA > Page 8914 8. Install stub shaft yoke (1) on U-joint cross (2). 9. Tap fist bearing cap into the stub shaft yoke bore far enough to position cross. 10. Position receiver/socket (1) on shaft yoke (2) and driver/socket on bearing cap in press. 11. Press bearing cap into stub shaft yoke until bearing cap snap ring groove is visible and install snap ring. 12. Position receiver/socket (1) on stub shaft yoke and driver/socket (2) on bearing cap in press. 13. Press bearing cap into stub shaft yoke until bearing cap snap ring groove is visible and install snap ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal Wheel Bearing: Service and Repair Front Hub / Bearing - Removal 4X4 - Independent Front Suspension 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal . 4. Remove the ABS wheel speed sensor if equipped, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor - Removal . 5. Remove the halfshaft nut. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod from the knuckle using remover 9360. 7. Remove the upper ball joint nut and separate the upper ball joint from the knuckle using remover 9360. 8. Pull down on the steering knuckle to separate the halfshaft (2) from the hub/bearing. 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. 2500 & 3500 - 4WD - Link/Coil 2500 & 3500 - 4WD 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the hub extension (1) mounting nuts and remove the extension from the rotor if equipped. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 8920 4. Remove the brake caliper, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Removal . 5. Remove the cotter pin (2) and the hub nut (1) from the axle shaft. 6. Remove the caliper adapter. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Removal . 7. Remove the disc brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal . 8. Disconnect the wheel speed sensor wire. 9. Remove the hub/bearing 4 mounting bolts and remove the hub/bearing. 4500 & 5500 - Link/Coil 4500 & 5500 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Removal . 4. Remove the caliper adapter. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Removal . 5. Remove the hub extension (2) and disc brake rotor (1) See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal . 6. Remove the axle shaft nut (3) from the axle shaft. 7. Disconnect the wheel speed sensor wire and remove the wheel speed sensor bolt (1) from the hub/bearing then remove the sensor (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 8921 8. Remove the hub/bearing 4 mounting bolts (1) and remove the hub/bearing. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 8922 Wheel Bearing: Service and Repair Front Hub / Bearing - Installation 4X4 - Independent Front Suspension 4X4 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation . 4. Install the ABS wheel speed sensor if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor - Installation . 5. Install the upper ball joint nut to the steering knuckle and tighten to 54 Nm (40 ft. lbs.) (on 1500 series only an additional 90° turn). 6. Install the tie rod end nut to the steering knuckle and tighten to 61 Nm (45 ft. lbs.) then an additional 90°. 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). 8. Install the wheel and tire assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement . 9. Remove the support and lower vehicle. 2500 & 3500 - 4WD - Link/Coil 2500 & 3500 - 4WD 1. Position the brake shield (1) on bolts. 2. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (2) to 202 Nm (149 ft. lbs. 3. Install the hub nut and tighten to 356 Nm (263 ft. lbs.). 4. Install the wheel speed sensor to the hub. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor - Installation . 5. Install the disc brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation . Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 8923 6. Install the brake caliper adapter with the caliper, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Installation . 7. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). HD DRW ONLY. 8. Install the wheel and tire assemblies, See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement . 9. Remove the support and lower the vehicle. 10. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. 4500 & 5500 - Link/Coil 4500 & 5500 NOTE: If installing a NEW hub/bearing on a 4X4 only Steps 1-3 should be followed for the correct shim size. 1. Measure from the new hub/bearing unit crimp (2) to the flange (3). 2. Choose the correct shim according to the table: 3. Check the shim (2) on the axle shaft (3). Be sure that the shim (2) is placed with the radius side (1) to the joint. 4. Install the hub/bearing to the knuckle. Tighten the hub/bearing bolts (1) to 202 Nm (149 ft. lbs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub / Bearing - Removal > Page 8924 5. Install the axle nut (3) and tighten to 356 Nm (263 ft. lbs.). 6. Install the wheel speed sensor 2) to the hub and tighten the bolt (1). See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Front Wheel Speed Sensor - Installation . 7. Install the disc brake rotor (1). See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation . 8. Install the hub extension (2) and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft.lbs). 9. Install the brake caliper adapter with the caliper, See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Installation . 10. Install the wheel and tire assemblies, See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement . 11. Remove the support and lower the vehicle. 12. Apply the brakes several times to seat the brake shoes and caliper piston. Do not move the vehicle until a firm brake pedal is obtained. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > 4X4 - Independent Front Suspension Axle Nut: Specifications 4X4 - Independent Front Suspension 4X4 Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > 4X4 - Independent Front Suspension > Page 8930 Axle Nut: Specifications 2500 & 3500 - 4WD - Link/Coil 2500 & 3500 - 4WD Install the hub nut and tighten to 356 Nm (263 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > 4X4 - Independent Front Suspension > Page 8931 Axle Nut: Specifications 4500 & 5500 - Link/Coil 4500 & 5500 Install the axle nut (3) and tighten to 356 Nm (263 ft. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Adjustments > Center Bearing LD Center Support: Adjustments Center Bearing LD BEARING CENTER Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 3.0 mm (0.125 in.) increments. Use shim stock or fabricated plates. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Adjustments > Center Bearing LD > Page 8937 Center Support: Adjustments Center Bearing HD BEARING CENTER Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 3.0 mm (0.125 in.) increments. Use shim stock or fabricated plates. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD Center Support: Service and Repair Center Bearing LD Removal REMOVAL 1. Remove rear propeller shaft. 2. Make installation reference marks on the shaft (1) and slip yoke (2). 3. Remove slip joint boot (1) clamp (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD > Page 8940 4. Slide boot (1) off boot collar (2) and separate the two shafts. 5. Position Bearing Splitter Tool 1130 (2) between slinger and center bearing (1). 6. Install Bridge 938 (3) on the splitter (2) and remove center bearing (1). Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD > Page 8941 1. Install new slinger on shaft if removed and drive into position with appropriate installer tool. 2. Install new center bearing (1) and boot collar (2) on shaft. 3. Install bearing (1) and boot collar (2) on shaft with Installer 6052 (3). 4. Clean shaft splines and apply a coat of multi-purpose grease. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD > Page 8942 5. Align master splines and slide front and rear half-shafts together. 6. Position slip yoke boot (1) on boot collar and install clamp (2). 7. Install propeller shaft in vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD > Page 8943 Center Support: Service and Repair Center Bearing HD Removal REMOVAL 2500 AND 3500 1. Remove rear propeller shaft. 2. Make installation reference marks on rear shaft (1) and front shaft (2). 3. Remove slip joint boot (1) clamp (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD > Page 8944 4. Slide boot (1) off boot collar (2) and separate the two shafts. 5. Position Bearing Splitter Tool 1130 (1) between propeller shaft and center bearing (2). 6. Install Bridge 938 (3) on the splitter (1) and remove center bearing. 4500 AND 5500 1. Remove rear propeller shaft. 2. Make installation reference marks on rear shaft, center bearing yoke (1) and front shaft (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD > Page 8945 3. Remove joint from center bearing yoke. 4. Remove center bearing yoke (1) nut (2) and washer (3). Discard yoke nut. 5. Remove center bearing yoke (1) from shaft with two jaw puller. 6. Position Bearing Splitter Tool 1130 (1) between propeller shaft and center bearing (2). 7. Install Bridge 938 (3) on the splitter (1) and remove center bearing. Installation INSTALLATION 2500 AND 3500 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD > Page 8946 1. Slide center bearing (1) and boot collar (2) on shaft. 2. Install boot collar (2) and center bearing (1) with Installer 6448A. 3. Clean shaft splines and apply a coat of multi-purpose grease. 4. Align master splines and slide front and rear half-shafts together. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD > Page 8947 5. Slide slip yoke boot (1) on boot collar (2). 6. Install slip yoke boot (1) clamp (2). 7. Install propeller shaft in vehicle. 4500 AND 5500 1. Slide center bearing (1) on shaft (2). 2. Install center bearing (1) with Installer MD 998805 (2). 3. Clean shaft splines and apply a coat of multi-purpose grease. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Center Bearing LD > Page 8948 4. Install center bearing yoke (1) and front shaft (2) with reference marks aligned. 5. Install center bearing yoke (1) new nut (2) and washer (3). 6. Tighten nut to 678 Nm (500 ft. lbs.). 7. Install joint in center bearing yoke (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications PROPELLER SHAFT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 8952 Drive/Propeller Shaft: Testing and Inspection PROPELLER SHAFT PROPELLER SHAFT VIBRATION Out-of-round tires or wheels that are out of balance, will cause a low frequency vibration. Driveline vibration can also be caused by loose or damaged engine mounts. Propeller shaft vibration increases with vehicle speed. A vibration that occurs at a specific speed range, is not usually caused by an out of balance propeller shaft. Defective universal joints or an incorrect propeller shaft angle are usually the cause of such a vibration. PROPELLER SHAFT BALANCE If propeller shaft is suspected of being out of balance, use the following procedure. NOTE: Indexing propeller shaft 180 degrees relative to the yoke may eliminate some vibrations. 1. Raise and support vehicle. 2. Clean all foreign material from the propeller shaft and universal joints. 3. Inspect propeller shaft for missing balance weights, broken welds and bent areas. If propeller shaft is bent, it must be replaced. 4. Inspect universal joints for wear and properly installed. 5. Check propeller shaft bolt torques. 6. Remove wheels and install lug nuts to retain brake rotors. 7. Mark and number the shaft six inches from the pinion yoke end at four positions 90 degrees apart. 8. Run and accelerate vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 8953 9. Install a screw clamp at position (1). 10. Start engine and check vibration. If there is little or no change move the clamp to the next positions. Repeat the vibration test. NOTE: If there is no difference in vibration at this positions, the vibration may not be the propeller shaft. 11. If vibration decreased, install a second clamp (1) and repeat the test. 12. If additional clamp causes an additional vibration, separate the clamps 1/2 inch (1) above and below the mark. Repeat the vibration test. 13. Increase distance between the clamp screws (1) (2) and repeat test, until the least amount of vibration is noticed. Bend the slack end of the clamps so screws will not loosen. 14. If vibration remains unacceptable, repeat the procedure to the front end of the propeller shaft. 15. Install wheels and lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures Drive/Propeller Shaft: Procedures Propeller Shaft Angle PROPELLER SHAFT ANGLE ONE PIECE PROPELLER SHAFT This procedure applies to front and rear propeller shafts. NOTE: To obtain output angle (A) on the front propeller shaft equipped with a C/V joint, place inclinometer on machined surface of the C/V joint. 1. Raise vehicle and support the axles as level as possible, allowing the wheels and propeller shaft to turn. 2. Remove universal joint snap rings if equipped, so inclinometer base sits flat. 3. Rotate shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always take measurements from front to rear and on the same side of the vehicle. 4. Place Inclinometer 7663 on yoke bearing cap or pinion flange ring parallel to the shaft. Center bubble in sight glass and record measurement (A). This measurement will give you the transmission yoke Output Angle (A). 5. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 8956 This measurement will give you the Propeller Shaft Angle (C). 6. Rotate propeller shaft 90 degrees and place inclinometer on companion flange yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement will give you the pinion Companion Flange Input Angle (B). 7. Subtract smaller figure from larger (C minus A) to obtain Transmission/Transfer Case Output Operating Angle. 8. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules and example for additional information. RULES - Good cancellation of U-joint operating angles should be within 1 degree. - Operating angles should be less than 3 degrees. - Operating angles less than 10 degrees for double cardan U-joint. - At least 1/2 of one degree continuous operating propeller shaft angle. TWO PIECE PROPELLER SHAFT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 8957 Two piece propeller shaft angles measurement is the same as a one-piece propeller shaft. Lubrication LUBRICATION Vehicles with double cardan universal joint front propeller shaft (1) are equipped with a grease fitting (2). Grease the double cardan universal joint at each oil change. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 8958 Drive/Propeller Shaft: Removal and Replacement Front LD REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove exhaust crossover pipe. 3. Mark a line across the axle companion flange (1), propeller shaft (2), flange yoke (3) and transfer case for installation reference. 4. Remove axle/transfer case companion flange bolts. Remove dust boot clamp (3) from the C/V joint (1) end of the shaft if equipped. 5. Remove propeller shaft. Front HD REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 8959 1. With vehicle in neutral, position vehicle on hoist. 2. Remove exhaust crossover pipe. 3. Mark a line across axle (3)/transfer case (2) companion flange and propeller shaft flange yokes for installation reference. 4. Remove axle/transfer case companion flange bolts. 5. Remove propeller shaft. Front LD INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 8960 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 8961 Drive/Propeller Shaft: Tools and Equipment PROPELLER SHAFT INSTALLER MD998805 SPLITTER 1130 INSTALLER 6052 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 8962 INSTALLER 6448A INCLINOMETER 7663 BRIDGE 938 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan Universal Joint: Service and Repair Universal Joints-Single Cardan Disassembly - With Injected Ring DISASSEMBLY - WITH INJECTED RING 1. Place shaft yoke in vise. 2. Position U-joint press (1) with receiver (2) on propeller shaft yoke. 3. Pressed U-joint bearing caps (1) out of shaft yoke (2). 4. Remove lower bearing cap from shaft yoke. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8967 5. Turn shaft over and position press (1) with receiver (2) on shaft yoke. 6. Press remaining U-joint bearing cap out of shaft yoke. 7. Remove flange (1) with U-joint out of shaft yoke (2). 8. Position U-joint press (2) with receiver (1) on flange. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8968 9. Press U-joint bearing caps (1) out of flange (2). 10. Remove bearing cap on the outside of the flange. 11. Position U-joint press (2) with receiver (1) on flange. 12. Press remaining U-joint bearing cap out of flange. 13. Remove U-joint from flange. Disassembly - With Snap Rings DISASSEMBLY - WITH SNAP RINGS 1. Tap outside of bearing cap with a drift to loosen snap ring. 2. Remove snap rings (1) from both sides of yoke. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8969 3. Position yoke with the grease fitting if equipped, pointing up. 4. Position a socket (2) with a inside diameter large enough to receive the bearing cap, beneath the yoke on a press. 5. Place another socket with an outside diameter smaller than bearing cap on the upper bearing cap and press (1) the lower cap through the yoke. NOTE: If bearing cap will not pull out of the yoke after pressing, tap yoke ear near bearing cap to dislodge the cap. 6. Pull bearing cap of the yoke. 7. Turn yoke over in the press and straighten the cross (1). Press the cross until the remaining bearing cap (2) can be removed. CAUTION: If cross or bearing cap are not straight during removal, the bearing cap will score the walls of the yoke bore and damage can occur. Assembly - With Injected Ring ASSEMBLY - WITH INJECTED RING Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8970 NOTE: Replacement joint has internal snap rings. 1. Place joint in flange with one bearing cap. 2. Position press (3) with receiver (1) on flange and bearing cap (2). 3. Press bearing cap until snap ring groove (1) is through the flange (2). 4. Install snap ring (2) on bearing (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8971 5. Position press (3) with receiver (2) on remaining bearing cap (1) and flange. 6. Press bearing cap until snap ring groove is through the flange. 7. Install snap ring (1) on bearing cap (2). 8. Install flange (1) with U-joint in yoke (2). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8972 9. Position press (2) with receiver (1) and lower bearing cap (3) on yoke. 10. Press bearing cap until snap ring groove is through the yoke. 11. Install snap ring (2) on bearing cap (1). 12. Position press (2) with receiver (3) on remaining bearing cap (1) and yoke. 13. Press remaining bearing cap until snap ring groove is through the yoke. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8973 14. Install snap ring (2) on bearing cap (1). Assembly - With Snap Rings ASSEMBLY - WITH SNAP RINGS 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Position cross (1) in yoke (2) with lube fitting pointing up, if equipped. 3. Place a bearing cap (1) over the cross end (2) and align cap with yoke bore. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8974 4. Press bearing cap into the yoke bore enough to clear snap ring groove. 5. Repeat STEP 3 and STEP 4 to install the opposite bearing cap. NOTE: If joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 6. Add grease to lube fitting, if equipped. 7. Install propeller shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8975 Universal Joint: Service and Repair Universal Joints-Double Cardan Disassembly DISASSEMBLY 1. Remove propeller shaft. 2. Mark propeller shaft, link yoke and flange yoke for assembly reference. 3. Tap outside of the bearing cap assembly with drift to loosen snap rings. 4. Remove all bearing cap snap rings. 5. Remove grease fittings if equipped. 6. Position a socket on the press with an inside diameter large enough to receive the bearing cap under the link yoke. 7. Place another socket with an outside diameter smaller than the bearing cap on the upper bearing cap. 8. Press one bearing cap from outboard side of the link yoke, enough to grasp the cap with vise jaws. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8976 9. Grasp protruding bearing cap with vise jaws and tap link yoke with a mallet to remove bearing cap. 10. Flip assembly and repeat STEP 6, STEP 7, STEP 8 and STEP 9 to remove the opposite bearing cap. 11. Remove cross centering kit assembly and spring. 12. Press remaining bearing caps out the other end of the link yoke. Assembly ASSEMBLY CAUTION: All alignment marks on the link yoke and propeller shaft yoke must be aligned during assembled. 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8977 2. Fit cross into the propeller shaft yoke. 3. Place bearing cap over the trunnion and align cap with the yoke bore. Keep needle bearings upright in the bearing cap. 4. Press bearing cap into yoke bore enough to clear snap ring groove and install snap-ring. 5. Flip propeller shaft yoke and install other bearing cap onto the opposite trunnion and install a snap ring. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8978 6. Fit link yoke onto remaining trunnions and press both bearing caps into place and install snap rings. 7. Install centering kit assembly inside the link yoke. NOTE: Verify spring is properly positioned. 8. Place two bearing caps on opposite trunnions of the remaining cross. Fit open trunnions into the link yoke bores and bearing caps into the centering kit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 8979 9. Press remaining two bearing caps into place and install snap rings. 10. Tap snap rings to seat them into the grooves. 11. Flexing the joint beyond center, the joint should snap over-center in both directions if correctly assembled. 12. Install propeller shaft. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Description and Operation Flywheel: Description and Operation DESCRIPTION STANDARD FLYWHEEL The standard (3) is a heavy plate bolted to the rear of the crankshaft (1). The flywheel incorporates the ring gear (2) around the outer circumference to mesh with the starter to permit engine cranking. The rear face of the flywheel serves as the driving member to the clutch disc. DUAL MASS FLYWHEEL The Dual Mass Flywheel (1) is used on the Diesel engine with G56 transmission. The flywheel incorporates the ring gear around the outer circumference to mesh with the starter to permit engine cranking. The primary flywheel side is bolted to an adapter plate which is bolted to the crankshaft. The secondary flywheel side (2) serves as the driving member to the clutch disc. Internal springs (3) are used to dampen energy. The Dual Mass Flywheel is serviced as an assembly only and should never be taken apart. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Description and Operation > Page 8983 Flywheel: Testing and Inspection FLYWHEEL Check flywheel (3) runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003 in.). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the indicator on a stud installed in place of one of the flywheel bolts. Common causes of runout are: - heat warpage - improper machining - incorrect bolt tightening - improper seating on crankshaft flange shoulder - foreign material on crankshaft flange Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour and machining will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180 grit emery or with surface grinding equipment. Remove only enough material to reduce scoring (approximately 0.001 - 0.003 in.). Heavy stock removal is not recommended. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 in.). Excessive stock removal can result in flywheel cracking or warpage after installation; it can also weaken the flywheel and interfere with proper clutch release. Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the flywheel causing excessive runout. Use new bolts when remounting a flywheel and secure the bolts with Mopar(TM) Lock And Seal or equivalent. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub causing runout. On a Dual Mass Flywheel (1) inspect all springs (2) for damage. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal Flywheel: Service and Repair Removal REMOVAL 1. Remove the transmission. NOTE: Vehicles with Dual Mass Flywheel use an adapter plate between the flywheel and crank. This plate does not need to be removed. 2. Remove the dust cover bolts (1) and the dust cover (2). 3. Using the access hole, remove each flexplate-to-flywheel bolt (1). Use Barring Tool 7471B to rotate the engine and flywheel. 4. Remove the assembly place the flywheel (1) , clutch disc (2) , and pressure plate (3) assembly on a workbench. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal > Page 8986 5. Loosen pressure plate bolts (1-8) evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove the eight pressure plate bolts (1-8) completely and remove pressure plate and disc. 7. Remove the flywheel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal > Page 8987 Flywheel: Service and Repair Installation INSTALLATION 1. Install flywheel on the crankshaft or adapter plate if vehicle has Dual Mass flywheel. 2. Install flywheel bolts and tighten evenly in sequence to 95 Nm (70 ft. lbs.). Vehicles with Dual Mass Flywheel, tighten adapter plate bolts to 55 Nm (40 ft. lbs.). 3. Install clutch. 4. Install transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Description Overdrive Indicator Lamp: Description and Operation Description DESCRIPTION An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Description > Page 8994 Overdrive Indicator Lamp: Description and Operation Operation OPERATION The overdrive off indicator gives an indication to the vehicle operator when the overdrive-OFF position of the tow/haul switch has been selected, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the overdrive off indicator for the following reasons: - Overdrive Off Indicator Lamp-On Message - Each time the cluster receives an electronic overdrive off indicator lamp-ON message from the PCM indicating that the overdrive-OFF position of the tow/haul switch has been selected, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, Refer to appropriate testing. For proper diagnosis of the transmission control system, the PCM, the EMIC, the CAN data bus or the electronic communication related to overdrive off indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description Temperature Warning Indicator - A/T: Description and Operation Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation > Description > Page 8999 Temperature Warning Indicator - A/T: Description and Operation Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). If the instrument cluster illuminates the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation > Description Transmission Mode Indicator - A/T: Description and Operation Description DESCRIPTION An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Each character appears in a blue-green color and at the same lighting level as the odometer information. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps are OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster general illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a PARADE mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation > Description > Page 9004 Transmission Mode Indicator - A/T: Description and Operation Operation OPERATION The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission type that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon an electronic selected gear message received from the Transmission Control Module (TCM) over the Controller Area Network (CAN) data bus. If the Transmission Range Sensor (TRS) mux circuit is open and no electronic selected gear messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the TRS. If the cluster is configured for an automatic transmission with a TRS input and detects a short to ground or an open in the TRS mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the TRS, then sends the proper message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles without a TCM, the EMIC continually monitors the hard wired TRS multiplexed input. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the EMIC, the CAN data bus or the electronic communication related to gear selector indicator operation a diagnostic scan tool is required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description Four Wheel Drive Indicator Lamp: Description and Operation Description 4WD Auto Indicator 4WD AUTO INDICATOR A 4WD auto indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD auto indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD auto indicator consists of a stencil-like cutout of the text 4WD AUTO in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD auto indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD auto indicator is serviced as a unit with the instrument cluster. 4WD Indicator 4WD INDICATOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 9010 A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional four-wheel drive system, this indicator is electronically disabled. The 4WD indicator is located on the right side of the instrument cluster, to the right of the oil pressure gauge. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. 4 Low Indicator 4 LOW INDICATOR A 4 low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4 low indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The 4 low indicator consists of a stencil-like cutout of the text 4 LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4 low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4 low indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 9011 Four Wheel Drive Indicator Lamp: Description and Operation Operation 4WD Auto Indicator 4WD AUTO INDICATOR The 4WD auto indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD auto mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD auto indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD auto indicator for the following reasons: - 4WD Auto Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD auto indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD auto indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD auto mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the 4WD auto indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD auto indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4WD Indicator 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly or the manual transfer case through the transfer case switch to determine when the 4WD mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transfer case shift motor/mode sensor, the transfer case switch, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. 4 Low Indicator 4 LOW INDICATOR The 4 low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Description > Page 9012 the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The 4 low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the 4 low indicator for the following reasons: - 4 Low Indicator Lamp-On Message - Each time the cluster receives an electronic 4 low indicator lamp-ON message from the TIPM, the indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the 4 low indicator will be turned ON, then OFF again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the 4 low indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the transfer case shift motor/mode sensor, the TIPM, the EMIC, the CAN data bus or the electronic communication related to 4 low indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page 9017 Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Totally Integrated Power Module (TIPM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the TIPM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-ON message from the TIPM, the service 4WD indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-OFF message from the TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the TIPM for 10 seconds the service 4WD indicator is illuminated by the cluster to indicate a loss of TIPM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The TIPM then sends the proper lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, Refer to appropriate testing. For proper diagnosis of the TIPM, the EMIC, the CAN data bus or the electronic communication related to service 4WD indicator operation a diagnostic scan tool is required. Refer to the appropriate diagnostic information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9024 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 9029 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Fluid Capacity G56 ...................................................................................................................................................... ......................................................... 5.9 L ( 12.4 Pt ) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 9032 Fluid - M/T: Fluid Type Specifications MANUAL TRANSMISSION LUBRICANT G56 ...................................................................................................................................................... ........................... Mopar ATF +4 Transmission Fluid Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 9033 Fluid - M/T: Description and Operation MANUAL TRANSMISSION NOTE: DaimlerChrysler recommends using Mopar(R) lubricants or lubricants of equal quality. - Getrag 238 - Mopar(R) ATF+4 Transmission Fluid - G 56 - Mopar(R) ATF+4 Transmission Fluid Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Diagrams Power Take-Off: Diagrams Component ID: 503 Component : SWITCH-PTO Connector: Name : SWITCH-PTO Color : # of pins : 1 Qualifier : (NGC) Pin Circuit Description 1 G113 20VT PTO SWITCH SENSE Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: Customer Interest A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9051 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9052 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift Control Module: All Technical Service Bulletins A/T Controls - Harsh 2-3 Upshift/Coast Downshift NUMBER: 21-019-07 GROUP: Transmission DATE: November 14, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. SUBJECT: FLASH: 68RFE Transmission - Harsh Coastdown Shift And/Or Harsh 2-3 Upshift OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission Control Module (1CM) with new software. MODELS: 2007 - 2008 (DH/D1) Ram Truck (2500/3500) NOTE: This bulletin applies to vehicles equipped with a 68RFE automatic transmission (sale code DG7) built on or before November 06, 2007 (MDH 1106XX). SYMPTOM/CONDITION: The customer may experience a harsh downshift from the transmission when coming to a stop. When a vehicle stop is initiated from 4th gear (around 40 Km/h or 25 MPH), the harsh downshift condition will usually occur as the vehicle decelerates to a speed of about 16Km/h (10MPH). If the transmission is in 2nd, 3rd, 5th, or 6th gear, when the stop is initiated, the condition will not be present. This may cause the condition to appear to be intermittent to the customer. Because the harsh downshift may occur below 16 Km/h (10 MPH), the customer may believe that they are experiencing a harsh 2 - 1 downshift. Some customers may also experience a harsh 2-3 upshift during normal acceleration. This symptom is less common than the harsh coastdown shift. DIAGNOSIS: 1. Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9058 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the website under the "download center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Place the ignition switch in the "RUN" position. Do not start engine. 5. Power ON the StarSCAN®. 6. Retrieve the old ECU (1CM) part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the TCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the TCM update is complete, select "OK". 7. Clear all DTC's from the vehicle electronic modules. NOTE: Due to the TCM programming procedure, a DTC may be set in other electronic modules within the vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 8. Using the StarSCAN(R), perform a transmission "Quick Learn" procedure prior to returning the vehicle to the customer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-019-07 > Nov > 07 > A/T Controls - Harsh 2-3 Upshift/Coast Downshift > Page 9059 NOTE: A "Quick Learn" must be performed. NOTE: The following step is required by law when reprogramming a PCM or TCM. 9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 Control Module: Locations Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 9062 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 9063 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 9064 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 9065 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 9066 Control Module: Locations Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 9067 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 9068 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 9069 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Component ID 200 > Page 9070 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 Control Module: Diagrams Component ID 200 Component ID: 200 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 9073 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 9074 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 9075 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 9076 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 9077 Control Module: Diagrams Component ID 216 Component ID: 216 Component : MODULE-TRANSMISSION CONTROL Connector: Name : MODULE-TRANSMISSION CONTROL C1 Color : # of pins : 17 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2-3 K427 18OR/LG POWER TAKEOFF RELAY ENABLE 4-5 T803 20DG/BR PRESSURE SIGNAL 4 6 T800 20DG/BR PRESSURE SIGNAL 1 7-8-9-10 - 11 T804 20YL/DB PRESSURE SIGNAL 5 12 T802 20DG/PK PRESSURE SIGNAL 3 13 - 14 - 15 - 16 T805 20DG/OR PRESSURE SIGNAL 6 17 T801 20DG/RD PRESSURE SIGNAL 2 Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 9078 Connector: Name : MODULE-TRANSMISSION CONTROL C2 Color : # of pins : 24 Qualifier : (RC) Pin Circuit Description 1 T72 20YL/DB 8 VOLT SUPPLY 2 T14 20DG/BR OUTPUT SPEED SIGNAL 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 3 T16 16YL/OR TRANSMISSION CONTROL OUTPUT Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 9079 4 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 5-6-7 A104 20YL/RD FUSED B(+) 8 Z133 18BK/LG GROUND 9-10 - 11 - 12 - 13 - - 14 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 15 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL 16 T819 20YL/VT TCC TEMPERATURE SIGNAL 17 Z133 18BK/LG GROUND 18 - 19 T811 20DG/LB SHIFT 4 CONTROL 20 D65 20WT/LG CAN C BUS (+) 21 D64 20WT/LB CAN C BUS (-) 22 - 23 - 24 - Component Location - 31 Connector: Name : MODULE-TRANSMISSION CONTROL C3 Color : # of pins : 31 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 9080 Pin Circuit Description 1 T808 20DG/GY SHIFT 1 CONTROL 2-3 T810 20DG/DB SHIFT 3 CONTROL 4-5 T817 20YL/BR LINEAR 3 CONTROL 6 T812 20DG/TN LINEAR 1 GROUND 7 T813 20DG/LG LINEAR 1 CONTROL 8 T815 20YL/RD LINEAR 2 CONTROL 9 T814 20YL/BR LINEAR 2 GROUND 10 T806 20DG/VT PRESSURE SIGNAL 7 11 - 12 - 13 - 14 - - 15 T816 20YL/PK LINEAR 3 GROUND 16 T828 20DG/DB TRS 1 SIGNAL 17 T42 20DG/YL TRS T42 SIGNAL 18 T3 20DG/DB TRS T3 SIGNAL 19 T827 20DG/LB TRS DRIVE SIGNAL 20 T824 20YL/DB TRS PARK SIGNAL 21 T826 20DG/DB TRS REVERSE SIGNAL 22 T809 20DG/YL SHIFT 2 CONTROL 23 - 24 - 25 - 26 T807 20DG/WT PRESSURE SIGNAL 8 27 - 28 T820 20YL/WT TEMPERATURE SENSOR GROUND 29 T825 20DG/YL TRS NEUTRAL SIGNAL 30 T821 20YL/GY LINEAR 4 CONTROL 31 T818 20YL/OR LINEAR 4 GROUND Component Location - 31 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Component ID 200 > Page 9081 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION On gasoline vehicles the Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Vehicles equipped 68RFE transmission and a 6.7L Diesel engine, the TCM is housed in the NGC4 controller utilizing only the C1 and C4 connectors (TCM only). The controller is located at the rear of the engine compartment, near the right inner fender. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 9084 On Cab Chassis models equipped with the AS68RC transmission the Transmission Control Module (TCM) has three electrical connectors and is located in the passenger compartment underneath of the left side of the dash panel. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 9085 Control Module: Description and Operation Transmission Control Module - Operation OPERATION RLE and RFE TRANSMISSIONS The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 9086 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 9087 SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 9088 AISIN AS68RC TRANSMISSION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Speed Sensor - Output Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Throttle position - Torque Reduction Confirmation - Engine Coolant Temperature - Exhaust Brake Status (if equipped) - PTO Request (if equipped) - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Exhaust Brake Cut Request (if equipped). - Solenoids. - Torque Reduction Request. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 9089 Some examples of TCM.indirect outputs are: - Transmission Temperature (to PCM). - PRNDL Position (to cluster/CCN). - PTO Status. In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI). - Storing and selecting appropriate Shift Schedules. - System self-diagnostics. - Diagnostic capabilities (with scan tool). Clutch filling time is continuously maintained when the vehicle is running. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations The Transmission Control Relay is not serviceable if equipped Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams DESCRIPTION - HOW TO USE WIRING DIAGRAMS DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9095 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9096 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9097 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9098 AT - Automatic Transmissions-Rear Wheel Drive MT - Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions DESCRIPTION - CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information DESCRIPTION - CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9099 Connector, Ground and Splice Information DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9100 connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams show the entire splice and provide references to other sections the splices serves. Splice Information only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Connector Pin-Outs shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9101 5. Release the Secondary Terminal Lock, if required (1). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9102 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9103 INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). See: Service Procedures/Wire Splicing 4. Insert the repaired wire into the connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9104 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing STANDARD PROCEDURE - WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9105 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9106 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9107 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9108 STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse (1) 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 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9109 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems DIAGNOSIS AND TESTING - WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9110 - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9111 Transmission Control System Relay: Connector Views Component ID: 246 Component : RELAY-TRANSMISSION Connector: Name : RELAY-TRANSMISSION Color : # of pins : 4 Pin Circuit Description 1 A916 16RD FUSED B(+) 2 T16 16YL TRANSMISSION CONTROL OUTPUT 3 F916 16YL/OR TRANSMISSION RELAY OUTPUT 4 Z420 18BK GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > AS68RC Automatic Transmission Transmission Control System Relay: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION The relay is supplied fused B+ voltage, energized by the TIPM, and is used to supply power to the TCM when the transmission is in normal operating mode. Operation OPERATION The TIPM energizes the transmission control relay. When the relay is "off", no power is supplied to the TCM and the transmission will not operate. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 Control Module: Locations Component ID 197 Component ID: 197 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 9119 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 9120 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 9121 Control Module: Locations Component ID 206 Component ID: 206 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 9122 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Component ID 197 > Page 9123 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 Control Module: Diagrams Component ID 197 Component ID: 197 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 9126 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 9127 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 9128 Control Module: Diagrams Component ID 206 Component ID: 206 Component : MODULE-FINAL DRIVE CONTROL Connector: Name : MODULE-FINAL DRIVE CONTROL Color : # of pins : 50 Qualifier : (POWER WAGON) A-A1 A121 14RD/YL FUSED B(+) A2 T520 16YL/OR FRONT LOCKER SOURCE A3 T526 16YL/WT REAR LOCKER SOURCE A4 Z935 16BK GROUND A5 Z935 16BK GROUND A6 T524 16YL/LG FRONT LOCKER RETURN A7 T528 16YL/GY REAR LOCKER RETURN A8 T521 20YL/BK LOCKER SENSOR SUPPLY A9 T537 20YL/LG LOCKER SWITCH SUPPLY A10 T523 20YL/BK LOCKER SENSOR SUPPLY A11 - A12 - A13 D65 20WT/LG CAN C BUS (+) A14 D64 20WT/LB CAN C BUS (-) B T527 20YL/TN REAR LOCKER SENSOR SENSE B1 T522 20YL/LB FRONT LOCKER SENSOR SENSE B2 T535 20YL/BR LOCKER SWITCH SENSE B3 - B4 - B5 - B6 - B7 F960 20PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START) B8 T536 20YL/WT SWITCH SUPPLY B9 - B10 - B11 T531 20YL/TN STABILIZER BAR SWITCH SENSE B12 T532 20YL/GY LOCKER OPEN ILLUMINATION SENSE B13 T533 20YL/LB LOCKER REAR ILLUMINATION SENSE B14 T534 20YL LOCKER FR/RR ILLUMINATION SENSE C T530 20YL/DG STABILIZER BAR DISENGAGE ILLUMINATION SENSE C1 T529 20YL/LG STABILIZER BAR ENGAGE ILLUMINATION SENSE C2 - C3 - - Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 9129 C4 - C5 - C6 - C7 - C8 - C9 - C10 - C11 - C12 - C13 - C14 - - D-E-F-G-H-Component Location - 29 Component Location - 28 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Component ID 197 > Page 9130 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description Control Module: Description and Operation Description DESCRIPTION The Transfer Case Control Module (TCCM) functionality now resides in the Totally Integrated Power Module (TIPM), refer to the TIPM information for location and additional information. The TIPM controls the 4X4 transfer case shift functions via the actuation of a shift motor and utilizing the feedback of a mode sensor assembly. Communication is via the CAN bus. Inputs include user selectable 4X4 modes that include 2WD, AWD, 4HI, 4LO, and Neutral (selections vary with the specific transfer case). Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9133 Control Module: Description and Operation Operation OPERATION The Transfer Case Control Module (TCCM) functionality in the Totally Integrated Power Module (TIPM) utilizes the input from the transfer case mounted mode sensor, the instrument panel mounted selector switch, and the following information from the vehicle's CAN bus to determine if a shift is allowed. - Engine RPM and Vehicle Speed - Diagnostic Requests - Manual Transmission and Brake Applied - PRNDL - Ignition Status - ABS Messages Once the TIP determines that a requested shift is allowed, it actuates the bi-directional shift motor as necessary to achieve the desired transfer case operating mode. The TIPM also monitors the mode sensor while controlling the shift motor to determine the status of the shift attempt. Several items can cause the requested shift not to be completed. If the TIPM has recognized a fault (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: - Level Zero - Normal Operation. - Level One - Only Mode Shifts Are Allowed. - Level Two - Only Mode Shifts and Shifts Into LOW Are Allowed (No Neutral Shifts Are Allowed). - Level Three - No Shifts Are Allowed The TIPM can also be operating in one of three possible power modes. These power modes are: - Full Power Mode is the normal operational mode of the module. This mode is achieved by normal CAN bus traffic being present and the ignition being in the RUN position. Reduced Power Mode will be entered when the ignition has been powered off. In this state, the module will shut down power supplied to external devices, and to electronic interface inputs and outputs. From this state the module can enter either Sleep Mode or Full Power Mode. To enter this mode, the module must receive an ignition message denoting that the ignition is off, or not receive any messages for 5 ±0.5 seconds. To exit this mode, the module must receive one ignition message that denotes that the ignition is in the RUN position. - Sleep Mode will be entered, from the Reduced Power Mode, when no CAN traffic has been sensed for 20 ±1 seconds. If during Sleep Mode the module detects CAN bus traffic, it will revert to the Reduced Power mode while monitoring for ignition messages. It will remain in this state as long as there is traffic other than run or start messages, and will return to Sleep mode if the bus goes without traffic for 20 ±1 seconds. SHIFT REQUIREMENTS If the TIPM is in full power mode and at functionality level zero, it uses the following criteria to determine if a shift is allowed. If any of the driver controllable conditions are not met once the shift request is recognized, the TIPM will solidly illuminate the source position's LED and flash the desired position's LED for all shifts except NEUTRAL. The NEUTRAL shift LED strategy will be discussed later. Mode shifts will be allowed regardless of transmission gear or vehicle speed, whenever the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector switch state indicates that a mode shift has been requested. - A valid mode sensor signal is being sensed by the TIPM. - Proper transmit/receive messages are occurring on the CAN bus. - Ignition key switch is in the RUN position. Range shifts will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - A change in the Selector Switch state indicating a range shift has been requested. - Transmission in NEUTRAL signal must be recognized for at least 1.5 seconds ±100 msec. (Automatic transmissions only) - Proper transmit/receive messages are occurring on the CAN bus. - Clutch signal is recognized for 500 msec ± 50 msec (Manual transmissions only). - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - A valid mode sensor signal is being sensed by the TIPM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9134 A shift into transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 4.0 seconds ±100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus. (Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position, engine off. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. A shift out of transfer case Neutral will be allowed only if all of the following conditions are met: - Front and rear wheel speed are within 21 km/h (13 mph). - The recessed Neutral Selection switch has been depressed continuously for 1.0 seconds ±100 msec while all shift conditions have been continuously met. - Transmission in NEUTRAL signal recognized from the bus.(Automatic transmissions only) - Clutch signal is recognized from the bus (Manual transmissions only). - Proper message transmissions/receptions are occurring on the CAN bus. - Vehicle speed is less than or equal to 4.8 km/h (3 mph). - Ignition key switch is in the RUN position. - Foot Brake is applied. - A valid mode sensor signal is being sensed by the TIPM. SHIFT SEQUENCES Once all the driver controllable conditions for the requested shift have been met, the TIPM begins a shift timer with a maximum duration of 1 second per 'D' channel transition. If the shift timer expires before the TIPM recognizes to correct mode sensor code, the shift is considered to have been blocked. The blocked shift will increment the blocked shift counter by one. The TIPM strategy for handling blocked shifts will be described later. The process the TIPM performs for the various shifts will be described first. RANGE AND MODE SHIFTS The process for performing all the range and mode shifts are the same. The following steps describe the process. - Allow time for Selector Switch debounce; 250 msec ±50 msec. - Extinguish the source gear's LED while flashing desired transfer case position's LED. - Engage the shift motor for a maximum of 1 second ±100 msec per 'D' channel transition in the destination gear's direction while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Solidly illuminate the selected gear's LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ±50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds ±100 msec. per 'D' channel. The TIPM waits for 2.0 seconds ±50 msec. and repeats the attempt to shift to the desired position. The exception to the preceding sequence is when a shift from 4L to 2WD/AWD is requested. If 2WD/AWD is requested from the 4L position, the transfer case is first driven to the 4H position. If the 4H position is reached, the transfer case is then driven back to the 2WD/AWD position and the shift is considered complete. If the transfer case does not reach any the 4H position, but is in the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is also considered complete. SHIFT OUT OF NEUTRAL The following steps describe the process for a shift out of NEUTRAL. - Extinguish the Neutral LED. - Engage the shift motor for a maximum of 1 second ±100 msec toward the transfer case 4H mode position while monitoring the mode sensor channel transitions. - Disengage the shift motor when the correct mode sensor code is recognized. - Extinguish the Neutral LED. - Transmit a bus message that the transfer case shift is complete. - If the desired mode sensor code is not received after the shift timer expires (ie. a blocked or other condition exists), stop driving the motor and wait for 200 msec ±50 msec. The shift motor is then reversed in the direction back toward the source gear for up to 1.0 seconds 100 msec. The Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9135 TIPM waits for 2.0 seconds ±50 msec. and repeats the attempt to shift to the desired position. - When the Neutral button is released, if the 4H position is the desired position, the shift is complete. Illuminate the 4H LED. - Otherwise when the Neutral button is released, if all of the shift requirements are being met then engage the shift motor towards the desired position for 1 second ±100 msec per 'D' channel. (if requirements for shifting are not met, illuminate the 4H LED and flash the destination LED as an indication to the driver that all of the driver controllable shift conditions are not being met). If this requires another range or mode shift, begin the range/mode shift process. - If the desired mode sensor code is not received after the shift timer expires (i.e. a blocked or other condition exists), refer to the Blocked Shift Strategy. BLOCKED SHIFT STRATEGY When a shift is commanded, the shift motor will be driven towards its destination position, except in the case of shifting out of Neutral if 4L was selected (the transfer case will shift to the 4H position first, before proceeding to 4L). If the shift is blocked on the way to the destination, the TIPM may attempt to drive the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case has reached a non-NEUTRAL 'D' channel during the shift re-attempts, the LED for the achieved gear position is illuminated and the shift attempts are stopped. To re-attempt the desired shift, the selector switch will need to be rotated to the current position until the switch debounce timer expires then a shift will need to be requested again. At the end of the 5th blocked attempt, the shift motor is driven towards the last known 'D' channel position. If this motor drive allows the transfer case to reach the 2WD/AWD 'D' channel, or the 2WD/AWD between gear position on the 4H side of 2WD/AWD, the shift is considered complete and the shift attempts are ended. If the mode sensor is in the NEUTRAL region at the expiration of the shift timer, the TIPM will continue to make the shift attempts according to the blocked shift strategy independent of whether or not the driver controlled conditions are met. For shifts from NEUTRAL, if all 5 attempts fail to reach the desired position (which by default is 4H), the motor will be driven to stall in the direction of 4H or 4L, depending on the achieved position. If the transfer case has reached the 2WD/AWD or 4L between gear position nearest the NEUTRAL positions and the shift conditions are no longer being met, the transfer case will be driven toward the corresponding 'D' channel. Otherwise, the transfer case will be driven in the direction opposite the last attempt with the desired target being 4H or 4L. If the transfer case reaches the 2WD/AWD 'D' channel when being driven in the 4H direction, then one final 1.0 second drive toward 4H is attempted. If the transfer case then reaches any of the 4H positions, the shift is considered complete and the 4H LED is illuminated. If the transfer case is still the 2WD/AWD position, the shift is considered complete and the 2WD/AWD LED is illuminated. NOTE: If after the 5th blocked shift and reversal attempt, if the transfer case position is in the NEUTRAL region, shift attempts will continue until a non-NEUTRAL 'D' channel is reached. SHIFT REVERSAL TARGETS If the shift timer expires (1 second per 'D' channel) and the transfer case has not reached the desired position, all shifts will attempt to return to their original position with the exceptions of: - If the intended shift is going to the High rail from Low and can't make it, but it can make the 2WD/AWD position, the motor stops at that position. The TIPM will not attempt to cross back over NEUTRAL if it does not have to. This means that there was a block on the first attempt to go to 4H and the transfer case has made it through NEUTRAL to a known good position, then the motor will go back only to the 2WD/4WD position and execute the remainder of the attempts from there. - For shifts out of NEUTRAL, any time a shift is commanded out of NEUTRAL, the system needs to get out. The TIPM should never go to NEUTRAL unless the driver is commanding it and all required conditions are being met ENCODER DRIFT CORRECTION Whenever a shift is completed, the TIPM stores the position in memory as the transfer case's intended position. The TIPM continuously monitors the mode sensor and if the mode sensor drifts toward into a NEUTRAL region sensor position for 2.0 seconds, the TIPM will perform a motor drive to correct the drift. The transfer case will be driven toward the intended position for 1.0 seconds 100 msec. The TIPM will wait for 2.0 seconds ±50 msec. and repeat the attempt to shift to the desired position. This will continue until the intended position is reached. SHIFT MOTOR BRAKING Two modes of shift motor braking are employed to improve shift performance, static and dynamic. Static shift motor braking is utilized under the following conditions: - Whenever the transfer case is in the 2WD/AWD or 4L 'D' channel position. - Whenever an invalid mode sensor code is present. Static motor braking is achieved by applying +12V on both shift motor wires. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Description > Page 9136 NOTE: Static Shift Motor Braking is independent of ignition key position. SHIFT ATTEMPT LIMIT To protect the transfer case system, the TIPM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of 'D' channel segment transitions that occur in any 30 second time period. If the number of segment transitions is 30 or greater, the system will go into a default mode. The default mode of operation for shifting is that the number of allowed 'D' channel transitions permitted to occur will be 3 over each 15 second ±100 msec calibrated window of time. After 5 minutes ±100 msec, the motor can be assumed to have cooled down and the system will revert to normal operation. The following rules also apply to the shift limit: - The attempt limit will not prevent shifts coming out of NEUTRAL, they will be allowed regardless of the counter/timer. - Any shift that is in progress when the counter reaches a maximum count in time will be allowed to complete before the default mode is entered. D-channel transitions during this period will not be counted towards the default mode limit. - A block, regardless of the direction, whether towards destination or back towards reversal target (shift timer expiring), will count as a value of 2 transitions towards the 30 segment transitions to go into default mode as defined above. Current attempt limit values are 30 transitions in 30 seconds and default mode values are 3 transitions every 15 seconds for 5 minutes. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9142 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9143 Fluid Pressure Sensor/Switch: Diagrams Component ID: 425 Component : SENSOR-LINE PRESSURE Connector: Name : SENSOR-LINE PRESSURE Color : BLACK # of pins : 4 Qualifier : (RFE) Pin Circuit Description 1 T160 20DG/WT SENSOR GROUND Pin Circuit Description 1 K900 20DB/DG SENSOR GROUND 2 F856 20YL/PK 5 VOLT SUPPLY 3 T38 20YL/BR LINE PRESSURE SIGNAL 4-- Component Location - 23 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9144 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description Fluid Pressure Sensor/Switch: Description and Operation Description DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, which is part of the pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the pump inlet. The system contains a Line Pressure Sensor, which is a direct input to the TCM. The line pressure sensor monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 9147 Fluid Pressure Sensor/Switch: Description and Operation Operation OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts, to ensure consistent shift quality. During all other operation, the desired line pressure value is adjusted based on torque level and other transmission requirements. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal Fluid Pressure Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pressure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > Removal > Page 9150 Fluid Pressure Sensor/Switch: Service and Repair Installation INSTALLATION 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Overdrive Switch: Locations Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9154 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9155 Overdrive Switch: Diagrams Component ID: 514 Component : SWITCH-TOW/HAUL OVERDRIVE OFF Connector: Name : SWITCH-TOW/HAUL OVERDRIVE OFF Color : NATURAL # of pins : 6 Pin Circuit Description 123 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SIGNAL 4 Z71 20LB/BK GROUND 5 T5 20DG/YL AUTOSTICK (ERS)-TOW/HAUL SIGNAL 6 T160 20DG/WT SENSOR GROUND Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9156 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 9157 Overdrive Switch: Testing and Inspection DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS The tow/haul overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check continuity of each component when diagnosis indicates this is necessary. Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9160 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9161 Overdrive Switch: Service and Repair 545RFE Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9162 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9163 Overdrive Switch: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9164 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9165 Overdrive Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL 1. Using a plastic trim tool, remove the tow/haul overdrive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 9166 2. Install the tow/haul overdrive off switch (3) into the connector (2). 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description Shift Solenoid Position Sensor/Switch: Description and Operation Description DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains the Transmission Range Sensor (TRS) and five pressure switches that feed information to the TCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Description and Operation > Description > Page 9171 Shift Solenoid Position Sensor/Switch: Description and Operation Operation OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 23 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts and 545RFE PRESSURE SWITCH STATES: A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal Shift Solenoid Position Sensor/Switch: Service and Repair Removal REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. See: Transmission Control Systems/Testing and Inspection/Programming and Relearning/Transmission Control Module/TCM Quick Learn 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Solenoid Position Sensor/Switch > Component Information > Service and Repair > Removal > Page 9174 Shift Solenoid Position Sensor/Switch: Service and Repair Installation INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body. Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 in.lbs.). 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 in.lbs.). 6. Install the valve body into the transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range Transmission Position Switch/Sensor: Locations Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9179 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9180 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9181 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9182 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9183 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9184 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9185 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9186 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9187 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9188 Transmission Position Switch/Sensor: Locations Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Sensor-Transmission Range > Page 9189 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range Transmission Position Switch/Sensor: Diagrams Sensor-Transmission Range Component ID: 444 Component : SENSOR-TRANSMISSION RANGE Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 10 Qualifier : (RC) Pin Circuit Description 1 T825 20DG/YL TRS NEUTRAL SIGNAL 2 T3 20DG/DB TRS T3 SIGNAL 3 T828 20DG/DB TRS 1 SIGNAL 4 F1 20PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) 5 T824 20YL/DB TRS PARK SIGNAL 6 Z157 16BK/LG GROUND 7 T42 20DG/YL TRS T42 SIGNAL 8 T827 20DG/LB TRS DRIVE SIGNAL 9 T826 20DG/DB TRS REVERSE SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9192 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9193 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9194 Connector: Name : SENSOR-TRANSMISSION RANGE Color : # of pins : 6 Qualifier : (RE) Pin Circuit Description 1-2 T117 20DG/YL TRS SIGNAL 3-4-- Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9195 5 T917 20YL/TN TRS RETURN 6 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9196 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9197 Connector: Name : SENSOR-TRANSMISSION RANGE Color : LT. GREEN # of pins : 10 Qualifier : (RLE) Pin Circuit Description 1 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 2-3 K900 20DB/DG SENSOR GROUND 4 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9198 5-6-7 T1 20DG/LB TRS T1 SIGNAL 8 T3 20DG/DB TRS T3 SIGNAL 9 T42 20DG/YL TRS T42 SIGNAL 10 T41 20YL/DB TRS T41 SIGNAL (P/N) Component Location - 20 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9199 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9200 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9201 Transmission Position Switch/Sensor: Diagrams Assembly-Transmission Solenoid/TRS Component ID: 21 Component : ASSEMBLY-TRANSMISSION SOLENOID/TRS Connector: Name : ASSEMBLY-TRANSMISSION SOLENOID/TRS Color : BLACK # of pins : 23 Qualifier : (RFE) Pin Circuit Description 1-2 T20 20DG/WT L/R CONTROL 3-4 T41 20YL/DB TRS T41 SIGNAL (P/N) 5 T42 20DG/YL TRS T42 SIGNAL 6-- 7 T60 20YL/GY OD SOLENOID CONTROL 8 T3 20DG/DB TRS T3 SIGNAL 9 T1 20DG/LB TRS T1 SIGNAL 10 T16 16YL/OR TRANSMISSION CONTROL OUTPUT 11 T48 20BR/YL 4C PRESSURE SIGNAL 12 T118 20DG LINE PRESSURE CONTROL 13 T4 20DG/RD TRS T2 SIGNAL 13 T4 20DG/LB TRS T2 SIGNAL 14 T50 20DG/PK L/R PRESSURE SIGNAL 14 T50 20YL/TN L/R PRESSURE SIGNAL 15 T147 20DG/YL 2C PRESSURE SIGNAL 16 T9 20DG/TN OD PRESSURE SIGNAL 17 T59 20YL/LB UD CONTROL 18 T29 20YL/WT UD PRESSURE SIGNAL 19 T259 20YL/DG 4C CONTROL 20 T219 20YL/LG 2C CONTROL 21 T140 20YL/GY MS CONTROL 22 T160 20DG/WT SENSOR GROUND 22 K900 20DB/DG SENSOR GROUND 23 T54 20DG/OR TRANSMISSION TEMPERATURE SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Sensor-Transmission Range > Page 9202 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Position Switch/Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The Transmission Range Sensor (TRS) has 3 primary functions: - Provide a PARK/NEUTRAL start signal to the engine controller and the starter relay. - Turn the Back-up lamps on when the transmission is in REVERSE and the engine (ignition) is on. - Provide a transmission range signal to the instrument cluster. The sensor is mounted in the transmission housing near the valve body, just above the pan rail. It's in the same position as the Park/Neutral switch on other transmissions. The TRS contacts a cammed surface on the manual valve lever. The cammed surface translates the rotational motion of the manual lever into the linear motion of the sensor. The cammed surface on the manual lever is comprised of two parts controlling the TRS signal: The insulator portion contacts the switch poppet when the manual lever is not in PARK or NEUTRAL. The manual lever itself contacts the poppet when the lever is in PARK or NEUTRAL; providing a ground for the signal from the starter relay and the appropriate engine controller. Operation OPERATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9205 As the switch moves through its linear motion contacts slide across a circuit board which changes the resistance between the range sensing pins of the switch. A power supply on the instrument cluster provides a regulated voltage signal to the switch. The return signal is decoded by the cluster, which then controls the PRNDL display to correspond with the correct transmission range. A bus message of transmission range is also sent by the cluster. In REVERSE range a second contact set closes the circuit providing power to the reverse lamps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9206 Transmission Position Switch/Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9207 Transmission Position Switch/Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION TRANSMISSION RANGE SENSOR The transmission range sensor (1) is mounted externally on the left side of the transmission case. Operation OPERATION The transmission range sensor prohibits the vehicle from starting in any gear other than park and neutral. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 9208 Transmission Position Switch/Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TRANSMISSION RANGE SENSOR (TRS) NOTE: For all circuit identification in the following steps, Refer to the appropriate Wiring Information. 1. Raise vehicle on suitable hoist. 2. Disconnect the vehicle's shift cable from the manual lever. 3. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 4. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Park/Neutral Position Sense pin of the TRS and the transmission case. The resistance should be less than 5 ohms. 5. If the resistance is greater than 5 ohms in either of the previous steps, check for a dirty contact between the tip of the TRS rod and the valve body manual lever. If the contact is OK, replace the TRS. 6. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Fused Ignition Switch Output and the Back-up Lamp feed pins of the TRS. The resistance should be less than 5 ohms. If the resistance is greater than 5 ohms, replace the TRS. 7. With the manual lever in the PARK position (the PARK position is with the manual lever moved to the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 522.2 ohms. If the resistance is not correct, replace the TRS. 8. With the manual lever in the REVERSE position (the REVERSE position is with the manual lever moved one detent forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 206.2 ohms. If the resistance is not correct, replace the TRS. 9. With the manual lever in the NEUTRAL position (the NEUTRAL position is with the manual lever moved two detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 108.6 ohms. If the resistance is not correct, replace the TRS. 10. With the manual lever in the DRIVE position (the DRIVE position is with the manual lever moved three detents forward of the full rearward position), measure the resistance between the Transmission Range Sensor MUX and the Transmission Range Sensor 5V Supply pins of the TRS. The resistance should be 59.9 ohms. If the resistance is not correct, replace the TRS. 11. With the manual lever in the SECOND position (the SECOND position is with the manual lever moved one detent rearward of the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 31.9 ohms. If the resistance is not correct, replace the TRS. 12. With the manual lever in the LOW position (the LOW position is with the manual lever moved to the full forward position), measure the resistance between the Transmission Range Sensor MUX and the Back-up Lamp feed pins of the TRS. The resistance should be 13.7 ohms. If the resistance is not correct, replace the TRS. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission Transmission Position Switch/Sensor: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9211 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9212 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9213 Transmission Position Switch/Sensor: Service and Repair 48RE (A-618) 4 Speed Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > AS68RC Automatic Transmission > Page 9214 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed Transmission Speed Sensor: Locations Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9219 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9220 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9221 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9222 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9223 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9224 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9225 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9226 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9227 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9228 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9229 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9230 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9231 Transmission Speed Sensor: Locations Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9232 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9233 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9234 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9235 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9236 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9237 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9238 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9239 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9240 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9241 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9242 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9243 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9244 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9245 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9246 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9247 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9248 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9249 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9250 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9251 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9252 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9253 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9254 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Sensor-Input Speed > Page 9255 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed Transmission Speed Sensor: Diagrams Sensor-Input Speed Component ID 399 Component ID: 399 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9258 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9259 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9260 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9261 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9262 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9263 Component ID 420 Component ID: 420 Component : SENSOR-INPUT SPEED Connector: Name : SENSOR-INPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9264 Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 21 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9265 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9266 Connector: Name : SENSOR-INPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T52 20DG/OR INPUT SPEED SIGNAL 2 T13 20DG/VT SPEED SENSOR GROUND Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9267 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9268 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9269 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9270 Transmission Speed Sensor: Diagrams Sensor-Output Speed Component ID 400 Component ID: 400 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9271 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9272 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9273 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9274 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9275 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9276 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9277 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9278 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9279 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9280 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9281 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9282 Component ID 430 Component ID: 430 Component : SENSOR-OUTPUT SPEED Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9283 Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL 2 T72 20YL/DB 8 VOLT SUPPLY Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9284 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9285 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9286 Connector: Name : SENSOR-OUTPUT SPEED Color : # of pins : 2 Qualifier : (RE) Pin Circuit Description 1 T14 18DG/BR OUTPUT SPEED SIGNAL 2 T13 18DG/VT SPEED SENSOR GROUND Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9287 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9288 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9289 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9290 Connector: Name : SENSOR-OUTPUT SPEED Color : BLACK # of pins : 2 Qualifier : (RFE/RLE) Pin Circuit Description 1 T14 20DG/BR OUTPUT SPEED SIGNAL Pin Circuit Description 1 T13 20DG/VT SPEED SENSOR GROUND Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9291 2 T13 20DG/VT SPEED SENSOR GROUND 2 T14 20DG/BR OUTPUT SPEED SIGNAL Component Location - 20 Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9292 Component Location - 19 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9293 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Sensor-Input Speed > Page 9294 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed Transmission Speed Sensor: Description and Operation 48RE (A-618) 4 Speed Description DESCRIPTION The speed sensor (1) is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Operation OPERATION Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9297 Transmission Speed Sensor: Description and Operation 68RFE Automatic Transmission Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Description DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the park gear teeth. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 48RE (A-618) 4 Speed > Page 9298 Transmission Speed Sensor: Description and Operation AS68RC Automatic Transmission Description DESCRIPTION INPUT AND OUTPUT SPEED SENSORS The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate DC square wave signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Operation OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the "teeth" of the gear pass by the sensor coil, an DC square wave is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an DC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission Transmission Speed Sensor: Service and Repair 68RFE Automatic Transmission Removal REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the transmission case. Installation INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Removal REMOVAL Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9301 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor (1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. Installation INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 in.lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9302 Transmission Speed Sensor: Service and Repair AS68RC Automatic Transmission Output Speed Sensor OUTPUT SPEED SENSOR OUTPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor from the transmission case. Input Speed Sensor INPUT SPEED SENSOR INPUT SPEED SENSOR 1. Raise and support the vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9303 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. Output Speed Sensor OUTPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. OUTPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the output speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the wiring connector onto the output speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC ATF as necessary. Input Speed Sensor INPUT SPEED SENSOR NOTE: Apply trans jell to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) AS68RC ATF. Soak all friction disks in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 68RFE Automatic Transmission > Page 9304 INPUT SPEED SENSOR 1. Lubricate the output speed sensor o-ring with MOPAR(R) AS68RC ATF. 2. Install the input speed sensor into the transmission case. 3. Tighten the bolt to 8 Nm (70 in.lbs.). 4. Install the electrical wiring connector onto the input speed sensor. 5. Lower vehicle. 6. Verify the transmission fluid level. Add MOPAR(R) AS68RC as necessary. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9308 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9309 Transmission Temperature Sensor/Switch: Diagrams Component ID: 445 Component : SENSOR-TRANSMISSION TEMPERATURE Connector: Name : SENSOR-TRANSMISSION TEMPERATURE Color : # of pins : 2 Qualifier : (RC) Pin Circuit Description 1 T819 20YL/VT TCC TEMPERATURE SIGNAL 2 T820 20YL/WT TEMPERATURE SENSOR GROUND Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 9310 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description Transmission Temperature Sensor/Switch: Description and Operation Description DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: - Determine shift lever position - Supply ground to the Starter Relay in Park and Neutral only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Description > Page 9313 Transmission Temperature Sensor/Switch: Description and Operation Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Five of these possible codes correspond to valid gear position, there are two codes for the neutral position and three are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission Transmission Temperature Sensor/Switch: Service and Repair 48RE Automatic Transmission Removal REMOVAL 1. Raise vehicle and position drain pan under the transmission range sensor (TRS). 2. Move the transmission manual lever to the manual LOW position. The manual LOW position is with the manual lever in the forward-most detent. 3. Disengage the wiring connector from the TRS. 4. Remove the two screws holding the TRS to the TRS mounting bracket. 5. Remove the TRS (3) from the TRS mounting bracket by pulling it straight out of the bracket. 6. If necessary, loosen the TRS mounting bracket (2) in the transmission case using Adapter 8581 (3). 7. If necessary, remove the TRS mounting bracket (2) from the transmission case. Installation INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 9316 1. Move the transmission manual shaft lever to the manual LOW position. 2. If necessary, install the TRS mounting bracket (2) into the transmission case. Using Adapter 8581 (3), tighten the mounting bracket to 34 Nm (300 in.lbs.). 3. Install the TRS (3) into the mounting bracket (2) with the wiring connector facing the front of the transmission. 4. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.). 5. Verify proper sensor operation (1-4). 6. Move the transmission manual shaft lever to the PARK position. 7. Connect TRS wiring connector to the TRS and lower vehicle. 8. Refill the transmission fluid to the correct level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 9317 Transmission Temperature Sensor/Switch: Service and Repair AS68RC Automatic Transmission Removal REMOVAL NOTE: Be certain the transmission is in the park lock position. TRANSMISSION RANGE SENSOR 1. Remove the shift cable from the manual shift lever (2). 2. Disconnect the wire harness from the transmission range sensor. 3. Remove the two nuts (3) from the control shaft. TRS REMOVAL/INSTALLATION Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 9318 4. Pry open the tabs on the stake washer (5), remove the nut (3) and the stake washer (5). 5. Remove the bolts (2). 6. Remove the transmission range sensor (1) from the transmission control shaft (4). Installation INSTALLATION 1. Install the transmission range sensor (3) onto the control shaft (5). 2. Install the stake washer and the nut (4) and hand tighten. 3. With the transmission in neutral install the alignment tool 9983 (6) onto the control shaft (5) and into the alignment hole (1). 4. Install the bolts (2). 5. After aligning the transmission range sensor, tighten the bolts (2) 12.5 Nm (9 ft.lbs.) 6. Remove the alignment tool 9983 (6) 7. Tighten the control shaft nut to 7 Nm (62 in.lbs.) 8. Bend the tabs on the stake washer and nut (4) in at least two places to lock in position. TRANSMISSION RANGE SENSOR Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > 48RE Automatic Transmission > Page 9319 9. Install the manual shift lever (2) onto the control shaft. 10. Install the inner nut (3) onto the control shaft. Tighten the inner nut to 12.5 Nm (9 ft.lbs). 11. Install the outer nut (3) onto the control shaft. While holding the inner nut, tighten the outer not to 12.5 Nm (9 ft.lbs) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection SWITCH-CLUTCH PEDAL POSITION 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Component ID: 515 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Circuit Description 1 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT 2-3 K977 20BR/WT MODE SELECT 4 E11 20OR/DB PANEL LAMPS CONTROL 5 Z905 20BK GROUND 6 G95 20VT/BR NEUTRAL INDICATOR 7 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9328 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9329 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9330 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9331 Four Wheel Drive Selector Switch: Diagrams Component ID: 515 Component : SWITCH-TRANSFER CASE SELECTOR Connector: Name : SWITCH-TRANSFER CASE SELECTOR Color : BLACK # of pins : 10 Qualifier : (ETC) Pin Circuit Description 1 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT 2-3 K977 20BR/WT MODE SELECT 4 E11 20OR/DB PANEL LAMPS CONTROL 5 Z905 20BK GROUND 6 G95 20VT/BR NEUTRAL INDICATOR 7 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) 8-9-10 - Component Location - 47 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9332 Component Location - 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9333 Component Location - 20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9334 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case Four Wheel Drive Selector Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9337 - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9338 Four Wheel Drive Selector Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and , T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9339 flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9340 Four Wheel Drive Selector Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, AWD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for AWD and in-between positions, the TCCM may interpret the resistance as: - the AWD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and , T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9341 flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9342 Four Wheel Drive Selector Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The selector switch assembly is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request. The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress. Operation OPERATION As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the table below: For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as: - either of the neighboring valid positions. - as an invalid fault position. For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as: - the 2WD position. - an invalid fault position. - a valid in-between position. For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as: Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Description and Operation > NV243 Transfer Case > Page 9343 - a valid in-between position. - an invalid fault position. For resistances between the ranges A and B shown for the fault condition (short) and T-Case NEUTRAL, the TCCM may interpret the resistance as: - the T-Case NEUTRAL position. - an invalid fault position. The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state. - A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed. - A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere See: Relays and Modules - Transmission and Drivetrain/Relays and Modules - Transfer Case/Control Module/Description and Operation/Operation is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift. - If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed. - No LED's illuminated indicate a fault in the transfer case control system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Locations Assembly-Shift Motor/Mode Sensor Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9348 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9349 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9350 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9351 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9352 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9353 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9354 Gear Sensor/Switch: Locations Sensor-Transfer Case Position Component ID: 443 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC EXCEPT POWER WAGON) Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A 2 Z955 20BK GROUND 2 Z955 18BK GROUND 2 Z901 20BK GROUND Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9355 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9356 Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC POWER WAGON) Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9357 2 G180 18VT/YL SENSOR RETURN 2 G180 20VT/YL SENSOR RETURN Component Location - 22 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Assembly-Shift Motor/Mode Sensor > Page 9358 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor Gear Sensor/Switch: Diagrams Assembly-Shift Motor/Mode Sensor Component ID 14 Component ID: 14 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9361 Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component ID 18 Component ID: 18 Component : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : BLACK # of pins : 8 Qualifier : (RFE FULL TIME ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B 5 T102 16YL SHIFT MOTOR CONTROL A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9362 6 A940 20RD FUSED B(+) 7 T300 20YL/GY T-CASE MOTOR BRAKE SIGNAL 8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9363 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9364 Connector: Name : ASSEMBLY-SHIFT MOTOR/MODE SENSOR Color : DK. GRAY # of pins : 8 Qualifier : (RFE PART TIME ETC/RE ETC) Pin Circuit Description 1 T103 20YL/OR 5 VOLT SUPPLY 2 D201 20WT/DG MODE SENSOR A 3 G180 20VT/YL SENSOR RETURN 4 T101 16DG SHIFT MOTOR CONTROL B Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9365 5 T102 16YL SHIFT MOTOR CONTROL A 6 A918 20RD FUSED B(+) 7-8-Component Location - 21 Component Location - 24 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9366 Component Location - 26 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9367 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9368 Gear Sensor/Switch: Diagrams Sensor-Transfer Case Position Component ID: 443 Component : SENSOR-TRANSFER CASE POSITION Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC EXCEPT POWER WAGON) Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A 2 Z955 20BK GROUND 2 Z955 18BK GROUND 2 Z901 20BK GROUND Component Location - 22 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9369 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9370 Connector: Name : SENSOR-TRANSFER CASE POSITION Color : # of pins : 2 Qualifier : (MTC POWER WAGON) Pin Circuit Description 1 D201 18WT/DG MODE SENSOR A Pin Circuit Description 1 D201 20WT/DG MODE SENSOR A Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9371 2 G180 18VT/YL SENSOR RETURN 2 G180 20VT/YL SENSOR RETURN Component Location - 22 Component Location - 25 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Assembly-Shift Motor/Mode Sensor > Page 9372 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case Gear Sensor/Switch: Description and Operation NV244 GENII Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9375 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9376 Gear Sensor/Switch: Description and Operation NV246 Transfer Case Description DESCRIPTION The transfer case mode sensor is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The FCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Front Control Module (FCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to the sensor codes returned to the FCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9377 Gear Sensor/Switch: Description and Operation NV271 Transfer Case Description DESCRIPTION The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case's current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. Operation OPERATION Position Sensor Linear Movement During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operating Mode Versus Resistance table for the correct resistance for each position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9378 Gear Sensor/Switch: Description and Operation NV243 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9379 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9380 Gear Sensor/Switch: Description and Operation NV273 Transfer Case Description DESCRIPTION The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA. Operation OPERATION During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined. Refer to SECTOR ANGLES vs.TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > NV244 GENII Transfer Case > Page 9381 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal Gear Sensor/Switch: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Disengage the transfer case position sensor connector from the position sensor. 3. Remove the position sensor from the transfer case. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Removal > Page 9384 Gear Sensor/Switch: Service and Repair Installation INSTALLATION 1. Inspect the o-ring seal on the transfer case position sensor. Replace the o-ring if necessary. 2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nm (20 ft.lbs.). 3. Engage the transfer case position sensor connector to the position sensor. 4. Lower vehicle. 5. Verify proper sensor operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front Speed Sensor: Locations Sensor-Prop Shaft Speed-Front Component ID: 435 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN 2 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 9389 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 9390 Speed Sensor: Locations Sensor-Prop Shaft Speed-Rear Component ID: 436 Component : SENSOR-PROP SHAFT SPEED-REAR Connector: Name : SENSOR-PROP SHAFT SPEED-REAR Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T70 20YL INPUT SPEED SENSOR 1 (N2) SIGNAL 2 T341 20DG/VT INPUT SPEED SENSOR 1 (N2) RETURN Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Locations > Sensor-Prop Shaft Speed-Front > Page 9391 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front Speed Sensor: Diagrams Sensor-Prop Shaft Speed-Front Component ID: 435 Component : SENSOR-PROP SHAFT SPEED-FRONT Connector: Name : SENSOR-PROP SHAFT SPEED-FRONT Color : # of pins : 2 Qualifier : (FULL TIME ETC) Pin Circuit Description 1 T71 20YL/OR INPUT SPEED SENSOR 2 (N3) RETURN 2 T340 20DG/VT INPUT SPEED SENSOR 2 (N3) SIGNAL Component Location - 21 Dodge Ram 2500 4wd Workshop Manual (Truck L6-6.7L DSL Turbo (2008)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Diagrams > Sensor-Prop Shaft Speed-Front > Page 9394